System and Process for Combusting Coal and Beneficiated Organic-Carbon-Containing Feedstock

ABSTRACT

A coal combustion process is described using coal and processed biomass to reduce adverse by-products in a coal combusting apparatus including the reduction of carbon dioxide by at least 50 volume %. The coal feedstock is selected from coal, a coal substitute processed biomass, or an aggregate blend of coal and processed biomass. The biomass feedstock comprises processed biomass pellets. The total energy density is predetermined and can be similar to the coal component or higher than the coal component. The intracellular salt in the processed biomass is at least 60 wt % less for the processed organic-carbon-containing feedstock used to make the processed biomass pellets than that of the starting un-processed processed organic-carbon-containing feedstock.

FIELD OF THE INVENTION

The present invention relates generally to coal burning devices and morespecifically to systems for heating boiler systems using fuel comprisingbiomass and coal.

BACKGROUND OF THE INVENTION

The vast majority of fuels are distilled from crude oil or obtained fromnatural gas pumped from limited underground reserves, or mined fromcoal. As the earth's crude oil supplies become more difficult andexpensive to collect and there are growing concerns about theenvironmental effects of coal other than clean anthracite coal, theworld-wide demand for energy is simultaneously growing. Over the nextten years, depletion of the remaining world's easily accessible crudeoil reserves, natural gas reserves, and low-sulfur bituminous coalreserves will lead to a significant increase in cost for fuel obtainedfrom crude oil, natural gas, and coal.

The search to find processes that can efficiently convert biomass tofuels and by-products suitable for transportation and/or heating is animportant factor in meeting the ever-increasing demand for energy. Inaddition, processes that have solid byproducts that have improvedutility are also increasingly in demand.

Biomass is a renewable organic-carbon-containing feedstock that containsplant cells and has shown promise as an economical source of fuel.However, this feedstock typically contains too much water andcontaminants such as water-soluble salts to make it an economicalalternative to common sources of fuel such as coal, petroleum, ornatural gas.

Historically, through traditional mechanical/chemical processes, plantswould give up a little less than 25 weight percent of their moisture.And, even if the plants were sun or kiln-dried, the natural and man-madechemicals and water-soluble salts that remain in the plant cells combineto create corrosion and disruptive glazes in furnaces. Also, theremaining moisture lowers the heat-producing million British thermalunits per ton (MMBTU per ton) energy density of the feedstock thuslimiting a furnace's efficiency. A BTU is the amount of heat required toraise the temperature of one pound of water one degree Fahrenheit, and 1MM BTU/ton is equivalent to 1.163 Gigajoules per metric tonne (GJ/MT).Centuries of data obtained through experimentation with a multitude ofbiomass materials all support the conclusion that increasingly largerincrements of energy are required to achieve increasingly smallerincrements of bulk density improvement. Thus, municipal waste facilitiesthat process organic-carbon-containing feedstock, a broader class offeedstock that includes materials that contain plant cells, generallyoperate in an energy deficient manner that costs municipalities money.Similarly, the energy needed to process agricultural waste, alsoincluded under the general term of organic-carbon-containing feedstock,for the waste to be an effective substitute for coal or petroleum arenot commercial without some sort of governmental subsidies and generallycontain unsatisfactory levels of either or both water or water-solublesalts. The cost to suitably transport and/or prepare such feedstock in alarge enough volume to be commercially successful is expensive andcurrently uneconomical. Also, the suitable plant-cell-containingfeedstock that is available in sufficient volume to be commerciallyuseful generally has water-soluble salt contents that result in adversefouling and contamination scenarios with conventional processes.Suitable land for growing a sufficient amount of energy crops to makeeconomic sense typically are found in locations that result in highwater-soluble salt content in the plant cells, i.e., often over 4000mg/kg on a dry basis.

Attempts have been made to prepare organic-carbon-containing feedstockas a solid renewable fuel, coal substitute, or binders for the making ofcoal aggregates from coal fines, but these have not been economicallyviable as they generally contain water-soluble salts that can contributeto corrosion, fouling, and slagging in combustion equipment, and havehigh water content that reduces the energy density to well below that ofcoal in large part because of the retained moisture. However, thereremains a need for biomass or biochar with coal as it is a cleanrenewable source of solid fuel if it could be made cost-effectively witha more substantial reduction in its content of water and water-solublesalt for use as coal substitutes or as high energy binders with coalfines.

Solid byproducts with improved beneficial properties are an importantfactor in meeting the ever-increasing demand for energy. The presentinvention fulfills these needs and provides various advantages over theprior art.

SUMMARY OF THE INVENTION

Embodiments of the present are directed to a coal combustion system in acoal combusting apparatus with less adverse by-products comprising afirst input chamber, a second input chamber, and a processed biomasssystem. The first input chamber of the coal combusting apparatus isconfigured to pulverize coal and feed it into the coal combustingapparatus in a first concentration of feedstock. The second chamber ofthe coal combusting apparatus is configured to pulverize processedbiomass pellets from a processed biomass system and feed it into thecoal combusting apparatus in a second concentration of feedstock withthe ratio of the first concentration to the second concentration between1 to 9 and 9 to 1. At least one exhaust chamber has a gaseous wastestream and comprising at least one gas separation sub-system configuredto separate at least 50 volume % of carbon dioxide from the gaseouswaste stream. A consumption sub-system configured to receive theseparated carbon dioxide gas and consume it in the making of usefulmaterials. The processed biomass system is configured to make processedbiomass from unprocessed organic-carbon-containing feedstock thatincludes free water, intercellular water, intracellular water,intracellular water-soluble salts, and at least some plant cellscomprising cell walls that include lignin, hemicellulose, andmicrofibrils within fibrils. The processed biomass system comprises abeneficiation sub-system and a pelletizing sub-system. The beneficiationsub-system is configured to convert the unprocessedorganic-carbon-containing feedstock into a processedorganic-carbon-containing feedstock with characteristics that includehaving an energy density of at least 17 MMBTU/ton (20 GJ/MT), a watercontent of less than 20 wt %, and a water-soluble intracellular saltcontent that is decreased more than 60 wt % on a dry basis from that ofthe unprocessed organic-carbon-containing feedstock. The pelletizingsub-system is configured to convert the processedorganic-carbon-containing feedstock into processed biomass pellets

Embodiments of the present, also directed to a coal combustion processfor combusting coal and processed biomass in a coal combusting apparatuswith less adverse by-products, comprises five steps. The first step isproviding coal feedstock to a first chamber of the coal combustingapparatus, the first chamber configured to pulverize coal and feed thecoal into the coal combusting apparatus in a first concentration offeedstock. The second step is making a processed biomass feedstockpellets in a processed biomass system that comprises three sub-steps.The first sub-step is inputting into the processed biomass a systemcomprising a first and a second subsystem an unprocessedorganic-carbon-containing feedstock that includes free water,intercellular water, intracellular water, intracellular water-solublesalts, and at least some plant cells comprising cell walls that includelignin, hemicellulose, and microfibrils within fibrils. The secondsub-step is passing unprocessed organic-carbon-containing feedstockthrough the first subsystem, a beneficiation sub-system via abeneficiation sub-system process to result in processedorganic-carbon-containing feedstock having characteristics that includehaving an energy density of at least 17 MMBTU/ton (20 GJ/MT), a watercontent of less than 20 wt %, and a water soluble intracellular saltcontent that is reduced by at least 60 wt % on a dry basis from that ofthe unprocessed organic-carbon-containing feedstock. The third sub-stepis passing the processed organic-carbon-containing feedstock through thesecond subsystem, a pelletizing sub-system via a pelletizing sub-systemprocess, to result in pelletized processed biomass pellets. The thirdstep is providing processed biomass feedstock pellets to a secondchamber of chamber of the coal combusting apparatus, the second chamberconfigured to pulverize the processed biomass pellets and feed theprocessed biomass into the coal combusting apparatus in a secondconcentration of feedstock with the ratio of the first concentration tothe second concentration between 1 to 9 and 9 to 1. The fourth step isto pass a gaseous waste stream of the coal combustion apparatus throughat least one exhaust chamber comprising at least one gas separationsub-system configured to separate at least 50 volume % of carbon dioxidefrom the gaseous waste stream and create separated carbon dioxide. Thefifth step is to pass the separated carbon dioxide through a gasconsumption sub-system configured to receive the separated carbondioxide gas and consume it in the making of useful materials.

The invention is a system and process for permitting the combustions ofcoal with less adverse by-products including the separation of at least50 volume % of carbon dioxide from the gaseous waste stream of the coalcombustion apparatus. By use of a novel processed biomass that may havean energy density in some embodiments that equals or exceeds that of anytype of coal and an intracellular salt content that is significantlyless than other biomass products of similar energy, a pulverized coalstream in a coal combusting apparatus may now be diluted with a streamof pulverized processed biomass at any ratio from 1 to 9 to 9 to 1. Thismay be done without the adverse effects of salt from conventional highenergy biomass. In addition, the coal in the coal stream may be blendedwith processed biomass in ratios from 1 to 9 to 9 to 1 to formaggregates that may be used in place of the coal in the coal stream tofurther dilute the adverse coal impurities without sacrificing energydensity. This latter option also provides a productive use of coal finesfrom coal mines that currently are difficult to transport because of thepotential for explosions.

The above summary is not intended to describe each embodiment or everyimplementation of the present invention. Advantages and attainments,together with a more complete understanding of the invention, willbecome apparent and appreciated by referring to the following detaileddescription and claims taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram of a typical plant cell with an exploded view of aregion of its cell wall showing the arrangement of fibrils,microfibrils, and cellulose in the cell wall.

FIG. 2 is a diagram of a perspective side view of a part of two fibrilsin a secondary plant cell wall showing fibrils containing microfibrilsand connected by strands of hemicellulose and lignin

FIG. 3 is a diagram of a cross-sectional view of a section of bagassefiber showing where water and water-soluble salts reside inside andoutside plant cells.

FIG. 4 is a diagram of a side view of an embodiment of a reactionchamber in a beneficiation sub-system.

FIG. 5A is a diagram of the front views of various embodiments ofpressure plates in a beneficiation sub-system.

FIG. 5B is a perspective view of a close-up of one embodiment of apressure plate shown in FIG. 5A.

FIG. 5C is a diagram showing the cross-sectional view down the center ofa pressure plate with fluid vectors and a particle of pith exposed tothe fluid vectors.

FIG. 6A is a graphical illustration of the typical stress-strain curvefor lignocellulosic fibril.

FIG. 6B is a graphical illustration of pressure and energy required todecrease the water content and increase the bulk density of typicalorganic-carbon-containing feedstock.

FIG. 6C is a graphical illustration of the energy demand multiplierneeded to achieve a bulk density multiplier.

FIG. 6D is a graphical illustration of an example of a pressure cyclefor decreasing water content in an organic-carbon-containing feedstockwith an embodiment of the invention tailored to a specific theorganic-carbon-containing feedstock.

FIG. 7 is a table illustrating the estimated energy consumption neededto remove at least 75 wt % water-soluble salt fromorganic-carbon-containing feedstock and reduce water content from 50 wt% to 12 wt % with embodiments of the beneficiation sub-system of theinvention compared with known processes.

FIG. 8 is a diagram of a side view of an embodiment of a beneficiationsub-system having four reaction chambers in parallel, a pretreatmentchamber, and a vapor condensation chamber.

FIG. 9 is a diagram of a side view of an embodiment of a horizontalsublimation oxygen-deficient thermal sub-system with a reactor chamberhaving one pass.

FIG. 10 is a diagram of a side view of an embodiment of a system with areaction chamber having two passes, a flexible shaft seal, and a hightemperature adjustable shaft cover plate.

FIG. 11A is a diagram of a side view of an embodiment of the flexibleshaft seal casing with the rope seals compressed in place.

FIG. 11B is a diagram of a view of an element of the embodiment of FIG.11A showing a back view of the frame holding the double rope seal.

FIG. 11C is a diagram of a view of an element of the embodiment of FIG.11A showing a back view of the frame holding a single rope seal.

FIG. 11D is diagram of a front view and side view of an element of theembodiment of FIG. 11A showing a cover that compresses the double ropeseal of FIG. 11B.

FIG. 11E is a diagram of a front view and side view of an element of theembodiment of FIG. 11A showing a cover that compresses the single ropeseal of FIG. 11C.

FIG. 12A is a diagram of the front view and side view of an embodimentof the high temperature adjustable cover plate showing a top half.

FIG. 12B is a diagram of the front view and side view of the embodimentof the high temperature adjustable cover plate of FIG. 12A showing abottom half.

FIG. 12C is a diagram of the front view of the embodiment of the hightemperature adjustable cover plate of FIG. 12A showing the top half ofFIG. 12A and the bottom half of FIG. 12B joined.

FIG. 12D is a diagram of the front view of the assembled hightemperature adjustable cover plate in the cold temperature position.

FIG. 12E is a diagram of the front view of the assembled hightemperature adjustable cover plate in the hot temperature position.

FIG. 13 is a diagram of a side view of an embodiment of a system with areaction chamber having two passes, a flexible shaft seal, a hightemperature adjustable shaft cover plate, and a high temperaturevertical support stand.

FIG. 14A is a front view of an embodiment of a vertical stand showing acurved cradle and a horizontal ring for passing coolant.

FIG. 14B is a top view of the embodiment of FIG. 14A showing the coolingring.

FIG. 14C is a front view of an embodiment of a vertical stand showing acurved cradle and a vertical up and down cooling passage within thevertical shaft of the vertical stand.

FIG. 15 is a diagram of a side view of an embodiment of a system with areaction chamber having two passes and a four-pass bypass manifoldattached to the outside of the reaction chamber to increase residencetime.

FIG. 16 is a diagram of a side view of an embodiment of a system with asubstantially horizontal reaction chamber having two passes, acompression chamber, and a drying chamber.

FIG. 17 is a diagram of a side view of an embodiment of a system with asubstantially vertical reaction chamber.

FIG. 17A is a diagram of the reaction tube array of the embodiment shownin FIG. 17.

FIGS. 18A and 18B illustrate side and cross sectional views,respectively, of a reaction chamber of an embodiment of a microwavesub-system configured to convert organic-carbon-containing materials tobiochar.

FIG. 18C is a diagram of a tilted reaction chamber of an embodiment ofthe microwave sub-system.

FIG. 18D is a diagram of a side view of an embodiment of the microwavesub-system.

FIG. 19A is a block diagram of an embodiment of the microwave sub-systemthat uses the reaction chamber illustrated in FIGS. 9A and 9B forwater/air extraction and a reaction process.

FIG. 19B illustrates an embodiment of the microwave sub-system thatincludes feedback control.

FIG. 20A shows a microwave sub-system which includes multiple stationarymagnetrons arranged on a drum that is disposed outside a cylindricalreaction chamber having one or more microwave-transparent walls.

FIG. 20B illustrates an embodiment of a microwave sub-system having adrum supporting magnetrons which may be rotated around the longitudinalaxis of the reaction chamber while the reaction chamber is concurrentlyrotated around its longitudinal axis;

FIG. 20C shows an embodiment of a microwave-sub system reaction chamberwith a feedstock transport mechanism comprising baffles.

FIG. 21 illustrates a system having a rotating magnetron in addition toa secondary heat source.

FIG. 22 depicts a microwave sub-system wherein a magnetron is movedalong the longitudinal axis of the reaction chamber and is rotatedaround the longitudinal axis of the reaction chamber.

FIG. 23 is a diagram of a system to make processed biomass made fromunprocessed organic-carbon-containing feedstock and co-fire them withcoal in a coal combustion apparatus.

FIG. 23A depicts a diagram of the system shown in FIG. 23 showing thecoal combustion apparatus with the gas separation sub-system and theconsumption sub-system for the removal of carbon dioxide from the gaswaste stream of the apparatus.

FIG. 24 is a block diagram of an embodiment of a process for passingunprocessed organic-carbon-containing feedstock through a beneficiationsub-system to create a processed organic-carbon-containing feedstockwith a water content of less than 20 wt % and a water-soluble saltcontent that is decreased by more than 60 wt % on a dry basis for theprocessed organic-carbon-containing feedstock from that of unprocessedorganic-carbon-containing feedstock.

FIG. 25 is a block diagram of an embodiment of a process for passingunprocessed organic-carbon-containing feedstock through a beneficiationsub-system to create a processed organic-carbon-containing feedstockwith a water content of less than 20 wt %, a water-soluble salt contentthat is decreased by more than 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of unprocessedorganic-carbon-containing feedstock, and an energy cost of removing thewater-soluble salt and water that is reduced to less than 60% of thecost per weight of similar removal from known mechanical, knownphysiochemical, or known thermal processes.

FIG. 26 is a table showing relative process condition ranges and waterand water-soluble salt content for three types oforganic-carbon-containing feedstock used in the beneficiationsub-system.

FIG. 27 is a block diagram of an embodiment of a process for passingprocessed organic-carbon-containing feedstock through a horizontalsublimation oxygen-deprived thermal sub-system to create a processedbiochar having an energy density of at least 17 MMBTU/ton (20 GJ/MT), awater content of less than 10 wt %, and water-soluble salt that isdecreased more than 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of unprocessedorganic-carbon-containing feedstock.

FIG. 28 is a block diagram of an embodiment of a process for passingprocessed organic-carbon-containing feedstock through a verticalsublimation oxygen-deprived thermal sub-system to create a processedbiochar having an energy density of at least 17 MMBTU/ton (20 GJ/MT), awater content of less than 10 wt %, and water-soluble salt that isdecreased more than 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of unprocessedorganic-carbon-containing feedstock.

FIG. 29 is a block diagram of an embodiment of a process for passingprocessed organic-carbon-containing feedstock through a microwavesub-system to create a solid renewable fuel processed biochar having anenergy density of at least 17 MMBTU/ton (20 GJ/MT), a water content ofless than 10 wt %, water-soluble salt that is decreased more than 60 wt% on a dry basis for the processed organic-carbon-containing feedstockfrom that of unprocessed organic-carbon-containing feedstock, and poresthat have a variance in pore size of less than 10%.

While the invention is amenable to various modifications and alternativeforms, specifics have been shown by way of example in the drawings andwill be described in detail below. It is to be understood, however, thatthe intention is not to limit the invention to the particularembodiments described. On the contrary, the invention is intended tocover all modifications, equivalents, and alternatives falling withinthe scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

Embodiments of the present invention are directed to a coal combustionsystem for combusting coal in a coal combusting apparatus with lessadverse by-products comprising a first chamber, a second chamber, a gasseparation sub-system, a consumption sub-system, and a processed biomasssystem. The first chamber of the coal combusting apparatus is configuredto pulverize coal and feed it into the coal combusting apparatus in afirst concentration of feedstock. The second chamber of the coalcombusting apparatus is configured to pulverize processed biomass from aprocessed biomass system and feed it into the coal combusting apparatusin a second concentration of feedstock with the ratio of the firstconcentration to the second concentration between 1 to 9 and 9 to 1.Once the coal and biomass are combusted to produce products such assteam for generating electricity, the gaseous waste stream from thecombustion are passed through a gaseous waste separation sub-system toremove at least 50 volume % of carbon dioxide. The separated carbondioxide is then passed through a consumption a sub-section to consumethe carbon dioxide in the making of products. The processed biomasssystem is configured to make processed biomass from unprocessedorganic-carbon-containing feedstock that includes free water,intercellular water, intracellular water, intracellular water-solublesalts, and at least some plant cells comprising cell walls that includelignin, hemicellulose, and microfibrils within fibrils. The processedbiomass system comprises a beneficiation sub-system and a pelletizingsub-system. The beneficiation sub-system is configured to convert theunprocessed organic-carbon-containing feedstock into a processedorganic-carbon-containing feedstock with characteristics that includehaving an energy density of at least 17 MMBTU/ton (20 GJ/MT), a watercontent of less than 20 wt %, and a water-soluble intracellular saltcontent that is decreased more than 60 wt % on a dry basis from that ofthe unprocessed organic-carbon-containing feedstock. The pelletizingsub-system is configured to convert the processedorganic-carbon-containing feedstock into processed biomass.

Now coal combustion can occur with significantly less adverseby-products. The cleaner processed biomass of the inventionsignificantly reduces intracellular salt that is common in conventionalbiomass. The higher energy density of the cleaner processed biomasspermits significant substation of the coal for processed biomass withoutany loss in energy to allow for a corresponding reduction is adverseimpurities brought in with the coal. In addition the major adverseby-produce remaining from the coal combustion, carbon dioxide, may nowbe reduced by at least 50 volume % in productive use operation. Thispermits coal combustion to be more environmentally friendly.

In some embodiments, the processed biomass is processed biochar havingan energy density of at least 21 MMBTU/ton (24 GJ/MT) and a watercontent that is less than 10 wt % such that the processed biochar iseven more able to have a dilution effect of the coal stream of reducingthe overall adverse impurities brought from the coal stream by bringlittle in the way of impurities to the combustion. The processed biomassof the invention has the advantages of being cleaner than coal andcoming from a renewable source, i.e., agricultural and plant materials,without the burdens of current biomass processes that are inefficientand remove less if any of the salt found in unprocessed renewablebiomass. There are several aspects of the invention that will bediscussed: coal, processed biomass, processed biochar, co-firing streamsof coal and processed biomass, unprocessed renewableorganic-carbon-containing feedstock, beneficiation sub-system, heatingsub-system, pelletizing/blending sub-system, gaseous separationsubsystem and consumption sub-system, beneficiation sub-system process,heating sub-system process, pelletizing/blending sub-system process, andgaseous separation subsystem and consumption sub-system process.

Coal

The term “coal” is used to describe a variety of fossilized plantmaterials, but no two coals are exactly alike. Heating value, ashmelting temperature, sulfur and other impurities, mechanical strength,and many other chemical and physical properties must be considered whenmatching specific coals to a particular application. Coal is classifiedinto four general categories, or “ranks” They range from lignite throughsub-bituminous and bituminous to anthracite, reflecting the progressiveresponse of individual deposits of coal to increasing heat and pressure.The carbon content of coal supplies most of its heating value, but otherfactors also influence the amount of energy it contains per unit ofweight. The amount of energy in coal is expressed in British thermalunits per ton or 2000 pounds. A BTU is the amount of heat required toraise the temperature of one pound of water one degree Fahrenheit. About90 percent of the coal in this country falls in the bituminous andsub-bituminous categories, which rank below anthracite and, for the mostpart, contain less energy per unit of weight. Bituminous coalpredominates in the Eastern and Mid-continent coal fields, whilesub-bituminous coal is generally found in the Western states and Alaska.Lignite ranks the lowest and is the youngest of the coals. Most ligniteis mined in Texas, but large deposits also are found in Montana, NorthDakota, and some Gulf Coast states.

The energy density of coal varies with its type with some overlap.Anthracite is coal with the highest carbon content, between 86 and 98percent, and an energy density or heat value of over 30 MMBTU/ton (35GJ/MT). Most frequently associated with home heating, anthracite is avery small segment of the U.S. coal market. There are 7.3 billion tonsof anthracite reserves in the United States, found mostly in 11northeastern counties in Pennsylvania. The most plentiful form of coalin the United States, bituminous coal is used primarily to generateelectricity and make coke for the steel industry. The fastest growingmarket for coal, though still a small one, is supplying heat forindustrial processes. Bituminous coal has a carbon content ranging from45 to 86 percent carbon and an energy density or heat value of 21MMBTU/ton to 31 MMBTU/ton (24 GJ/MT to 36 GJ/MT). Ranking belowbituminous is sub-bituminous coal with 35-45 percent carbon content andan energy density or heat value between 16.6 MMBTU/ton to 26 MMBU/ton(19 GJ/MT to 30 GJ/MT). Reserves are located mainly in a half-dozenWestern states and Alaska. Although its heat value is lower, this coalgenerally has a lower sulfur content than other types, which makes itattractive for use because it is cleaner burning. Lignite is ageologically young coal which has the lowest carbon content, 25-35percent, and an energy density or heat value ranging between 8 MMBTU/tonto 16.6 MMBTU/ton (9 GJ/MT to 19 GJ/MT). Sometimes called brown coal, itis mainly used for electric power generation. As used in this document,coal of any type that has an energy density of at least 21 MMBTU/ton (24GJ/MT) will be called high energy coal and coal of any type having anenergy density of less than 21 MMBTU/ton (24 GJ/MT) will be called lowenergy coal.

Coal has inorganic impurities associated with its formation undergroundover millions of years. The inorganic impurities are not combustible,appear in the ash after combustion of coal in such situations as, forexample boilers, and contribute to air pollution as the fly ashparticulate material is ejected into the atmosphere followingcombustion. The inorganic impurities result mainly from clay mineralsand trace inorganic impurities washed into the rotting biomass prior toits eventual burial. An important group of precipitating impurities arecarbonate minerals. During the early stages of coal formation, carbonateminerals such as iron carbonate are precipitated either as concretions(hard oval nodules up to tens of centimeters in size) or as infillingsof fissures in the coal. Impurities such as sulfur and trace elements(including mercury, germanium, arsenic, and uranium) are chemicallyreduced and incorporated during coal formation. Most sulfur is presentas the mineral pyrite (FeS₂), sulfate minerals (CaSO₄ and FeSO₄), ororganic complexes, and this may account for up to a few percent of thecoal volume. Burning coal oxidizes these compounds, releasing oxides ofsulfur (SO, SO₂, SO₃, S₇O₂, SO₆O₂, S₂O₂, etc.), notorious contributorsto acid rain. The trace elements (including mercury, germanium, arsenic,and uranium) were significantly present in the coal are also released byburning it, contributing to atmospheric pollution.

In some embodiments of this invention, coal may be substituted entirelyor in part by processed biomass, particularly processed biochar or by acoal/processed biomass compact blend aggregate.

Processed Biomass

Biomass made from renewable organic-carbon-containing feedstock by thebeneficiation process is referred to as processed biomass in thisdocument. The processed biomass of the invention comprises a solidcarbon fuel comprising less than 20 wt % water, and water-solubleintracellular salt that is less than 60 wt % on a dry basis that ofunprocessed organic-carbon-containing feedstock. The processed biomassis made from unprocessed organic-carbon-containing feedstock that isconverted into a processed organic-carbon-containing feedstock in abeneficiation sub-system. As used in this document, processed biomasspellets are a solid product of beneficiated organic-carbon-containingfeedstock that is subsequently pelletized. Organic-carbon-containingfeedstock used to make the processed biomass of the invention cancontain mixtures of more than one renewable feedstock.

The processed biomass component of high energy aggregates of theinvention is cleaner than coal. The impurities discussed above are notpresent in any significant amount. In particular, processed biomasscontains substantially no sulfur. Some embodiments have a sulfur contentof less than 1000 mg/kg (0.1 wt %) or less than 1000 parts per million(ppm), some of less than 100 mg/kg (100 ppm, some of less than 10 mg/kg(10 ppm). In contrast coal has significantly more sulfur. The sulfurcontent in coal ranges of from 4000 mg/kg (0.4 wt %) to 40,000 mg/kg (4wt %) and varies with type of coal. The typical sulfur content inanthracite coal is from 6000 mg/kg (0.6 wt %) to 7700 mg/kg (0.77 wt %).The typical sulfur content in bituminous coal is from 7000 mg/kg (0.7 wt%) to 40.000 mg/kg (4 wt %). The typical sulfur content in lignite coatis about 4000 mg/kg (0.4 wt%). Anthracite coal is too expensive forextensive use in burning. Lignite is poor quality coal, with a lowenergy density or BTU/wt.

In addition, processed biomass has substantially no nitrate, arsenic,mercury or uranium. Some embodiments have a nitrate content of less than500 mg/kg (500 ppm), some of less than 150 mg/kg (150 ppm), versus anitrate content in coal of typically over 20,000 mg·kg (2 wt %). Someembodiments have a arsenic content of less than 2 mg/kg (2 ppm), some ofless than 1 mg/kg (1 ppm), some less than 0.1 mg/kg or 100 parts perbillion (ppb), and some less than 0.01 mg/kg, (10 ppb) versus a arseniccontent in coal of from over 1 mg/kg to over 70 mg/kg (1 ppm to 70 ppm).Some embodiments have a mercury content that is negligible, i.e., lessthan 1 microgram/kg (1 ppb), versus mercury content in coal of from 0.02mg/kg (20 ppb) to 0.3 mg/kg (300 ppb). Similarly, some embodiments havea uranium content that is also negligible, i. e., less than 1microgram/kg (1 ppb), versus a uranium content in coal of from 20 mg/kg(20 ppm) to 315 mg/kg (315 ppm) with an average of about 65 mg/kg (ppm)and the uranium content in the ash from the coal with an average ofabout 210 mg/kg (210 ppm).

Processed Biochar

Char made from renewable organic-carbon-containing feedstock by thebeneficiation process is referred to as processed biochar in thisdocument. The processed biochar of the invention comprises a solidcarbon fuel comprising less than 10 wt % water, and water-soluble saltthat is less than 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of unprocessedorganic-carbon-containing feedstock. The water-soluble intracellularsalt content decrease is based on comparing the processedorganic-carbon-containing feedstock before it is passed through theheating sub-system to the unprocessed organic-carbon-containingfeedstock because the heating process can lower the wt of the solidbiomass on a dry basis as some is converted to biooils and biogases andremoved as discussed below under the heating subsystem section. Theprocessed biochar is made from unprocessed organic-carbon-containingfeedstock that is converted into a processed organic-carbon-containingfeedstock in a beneficiation sub-system, and that is then passed throughan oxygen-deprived thermal sub-system. As used in this document,processed biochar is the solid product of the devolatization ofbeneficiated organic-carbon-containing feedstock.Organic-carbon-containing feedstock used to make the processed biocharof the invention can contain mixtures of more than one renewablefeedstock.

Other forms of char are also known. Some of these chars include, forexample, char made by the pyrolysis of biomass, also known as charcoal.Charcoal has an energy density of about 26 MMBTU/ton (30 GJ/MT) andcontains all of the water-soluble salt residues found in the startingbiomass used to make the charcoal. Charcoal has various uses including,for example, a combustible fuel for generating heat for cooking andheating, as well as a soil amendment to supply minerals for fertilizingsoils used for growing agricultural and horticultural products. Char hasalso been made by passing biomass through an open microwave oven similarto a bacon cooker that is exposed to the external atmosphere containingoxygen and contains pores with a variance similar to that made by athermal process that has a liquid phase.

In contrast, the processed biomass component of high energy aggregatesof the invention is cleaner than coal. The impurities discussed aboveare not present in any significant amount. In particular, processedbiomass contains substantially no sulfur. Some embodiments have a sulfurcontent of less than 1000 mg/kg (0.1 wt %) or less than 1000 parts permillion (ppm), some of less than 100 mg/kg (100 ppm, some of less than10 mg/kg (10 ppm). In contrast coal has significantly more sulfur. Thesulfur content in coal ranges of from 4000 mg/kg (0.4 wt %) to 40,000mg/kg (4 wt %) and varies with type of coal. The typical sulfur contentin anthracite coal is from 6000 mg/kg (0.6 wt %) to 7700 mg/kg (0.77 wt%). The typical sulfur content in bituminous coat is from 7000 mg/kg(0.7 wt %) to 40,000 mg/kg (4 wt %). The typical sulfur content inlignite coal is about 4000 mg/kg (0.4 wt %). Anthracite coal is tooexpensive for extensive use in burning. Lignite is poor quality coal,with a low energy density or BTU/wt.

In addition, processed biomass has substantially no nitrate, arsenic,mercury or uranium. Some embodiments have a nitrate content of less than500 mg/kg (500 ppm), some of less than 150 mg/kg (150 ppm), versus anitrate content in coal of typically over 20,000 mg·kg (2 wt %). Someembodiments have a arsenic content, of less than 2 mg/kg (2 ppm), someof less than 1 mg/kg (1 ppm), some less than 0.1 mg/kg or 100 parts perbillion (ppb), and some less than 0.01 mg/kg (10 ppb) versus a arseniccontent in coal of from over 1 mg/kg to over 70 mg/kg (1 ppm to 70 ppm).Some embodiments have a mercury content that is negligible i. e., lessthan 1 microgram/kg (1 ppb), versus mercury content in coal of from 0.02mg/kg (20 ppb) to 0.3 mg/kg (300 ppb). Similarly, some embodiments havea uranium content that is also negligible, i.e., less than 1microgram/kg (1 ppb), versus a uranium content in coal of from 20 mg/kg(20 ppm) to 315 mg/kg (315 ppm) with an average of about 65 mg/kg, (ppm)and the uranium content in the ash from the coal with an average ofabout 210 mg/kg (210 ppm).

Other forms of char are also known. Some of these chars include, forexample, char made by the pyrolysis of biomass, also known as charcoal.Charcoal has an energy density of about 26 MMBTU/ton (30 GJ/MT) andcontains all of the water-soluble salt residues found in the startingbiomass used to make the charcoal. Charcoal has various uses including,for example, a combustible fuel for generating heat for cooking andheating, as well as a soil amendment to supply minerals for fertilizingsoils used for growing agricultural and horticultural products. Char hasalso been made by passing biomass through an open microwave oven similarto a bacon cooker that is exposed to the external atmosphere containingoxygen and contains pores with a variance similar to that made by athermal process that has a liquid phase.

In biochar made by thermal heat or infrared radiation, the heat isabsorbed on the surface of any organic-carbon-containing feedstock andthen is re-radiated to the next level at a lower temperature. Thisprocess is repeated over and over again until the thermal radiationpenetrates to the inner most part of the feedstock. All the material inthe feedstock absorbs the thermal radiation at its surfaces anddifferent materials that make up the feedstock absorb the IR atdifferent rates. A delta temperature of several orders of magnitude canexist between the surface and the inner most layers or regions of thefeedstock. As a result, the solid organic-carbon-containing feedstocklocally passes through a liquid phase before it is volatilized. Thisvariation in temperature may appear in a longitudinal direction as wellas radial direction depending on the characteristics of the feedstock,the rate of heating, and the localization of the heat source. Thisvariable heat transfer from the surface to the interior of the feedstockcan cause cold and hot spots, thermal shocks, uneven surface andinternal expansion cracks, fragmentation, eject surface material andcreate aerosols. All of this can result in microenvironments that causeside reactions with the creation of many different end products. Theseside reactions are not only created in the feedstock but also in thevolatiles that evaporate from the feedstock and occupy the vapor spacein the internal reactor environment before being collected.

A common thermal process, pyrolysis, produces biochar, liquids, andgases from biomass by heating the biomass in a low/no oxygenenvironment. The absence of oxygen prevents combustion. Typical yieldsare 60% bio-oil, 20% biochar, and 20% volatile organic gases. Hightemperature pyrolysis in the presence of stoichiometric oxygen is knownas gasification, and produces primarily syngas. By comparison, slowpyrolysis can produce substantially more char, on the order of about50%.

Another thermal process is a sublimation process that produces biocharand gases from biomass in a low/no oxygen environment. The absence ofoxygen also prevents combustion. Typical yields are 70% fuel gas and 30%biochar. Sublimation can occur in a vertical manner that lends itself toheavier/denser biomass feedstock such as, for example, wood and ahorizontal manner that lends itself to lighter/less dense biomassfeedstock such as, for example, wheat straw.

An alternative to thermal processes, the process to make char bymicrowave radiation uses heat that is absorbed throughout theorganic-carbon-containing feedstock. The process uses microwaveradiation from the oxygen-starved microwave process system. Withmicrowave radiation, the solid part of the feedstock is nearlytransparent to the microwave radiation and most of the microwaveradiation just passes through. In contrast to the small absorption crosssection of the solid feedstock, gaseous and liquid water strongly absorbthe microwave radiation increasing the rotational and torsionalvibrational energy of the water molecules. Therefore, the gaseous andliquid water that is present is heated by the microwaves, and thesewater molecules subsequently indirectly heat the solid feedstock. Thusany feedstock subjected to the microwave radiation field is exposed tothe radiation evenly, inside to outside, no matter what the physicaldimensions and content of the feedstock. With microwaves, the radiationis preferentially absorbed by water molecules that heat up. This heat isthen transferred to the surrounding environment resulting in thefeedstock being evenly and thoroughly heated.

In all of the above processes, water-soluble salt that is in allrenewable organic-carbon-containing feedstock is not removed This hasthe adverse effect of increasing ash content in combusted char andincreasing wear and maintenance costs from corrosion and slagging, adeposition of a viscous residue of impurities during combustion. Incontrast, the process to make the processed biochar of the inventionused a beneficiation sub-system to process the unprocessedorganic-carbon-containing feedstock to remove most of the water andwater-soluble salts, and an oxygen-deficient thermal sub-system toconvert the processed organic-carbon-containing feedstock into aprocessed biochar.

In contrast, the processed biochar of an embodiment of the inventioncontains much less water-soluble salt than that of currently knownbiochar. The oxygen-deficient thermal sub-system of the invention aresimilar to those discussed above but use a processedorganic-carbon-containing feedstock rather than an unprocessedorganic-carbon-containing feedstock used by the above oxygen-deficientthermal processes mentioned above.

Co-Firing Streams of Coal and Biomass

The invention is a system and process for permitting the combustions ofcoal with less adverse by-products. Current plants, typically powerplants, that have at least one coal combusting apparatus, are concernedabout the undesirably high levels of salt in biomass feedstock thatcause undesirable equipment wear if too much biomass feedstock is usedto supplement coal. Often a satisfactory amount of biomass is less than10-20 wt % of the total amount of solid fuel. By use of a novelprocessed biomass of the invention that may have an energy density insome embodiments that equals or exceeds that of any type of coal, awater content that is less than 20 wt %, and an intracellular saltcontent that is significantly less than other biomass products ofsimilar energy, a pulverized coal stream in a coal combusting apparatusmay now be diluted with a stream of pulverized processed biomass at anyratio from 1 to 9 to 9 to 1 on a wt % basis. In some embodiments theratio of the coal stream to the processed biomass stream on a wt basisis at least 1:9, in some at least 2:8, in some at least 3:7, in some atleast 4:6, in some at least 5:5, in some at least 6:4, in some at least7:3, in some at least 8:2, and in some at least 9:1. This may be donewithout the adverse effects of salt from conventional high energybiomass. In addition, the coal in the coal stream may be blended withprocessed biomass in ratios on a wt % basis of from 1 to 9 to 9 to 1 toform aggregates that may be used in place of the coal in the coal streamto further dilute the adverse coal impurities without sacrificing energydensity. In some embodiments the ratio of the coal to the processedbiomass in the blended aggregate on a wt basis is at least 1:9, in someat least 2;8, in some at least 3:7, in some at least 4:6, in some atleast 5:5, in some at least 6:4, in some at least 7:3, in some at least8:2, and in some at least 9:1. This latter option also provides aproductive use of coal fines from coal mines that currently aredifficult to transport because of the potential for explosions.

As stated above, some embodiments may use blended aggregates of coal andprocessed biomass to replace the coal that is pulverized in the firstchamber of the coal combusting apparatus with significantly cleaner fuelfor use in such processes as boilers without a commonly associatedreduction energy density.

Use of processed biomass with coal or with processed biomass/coalblended compact aggregate have several improved characteristics whencompared to a conventional stream of biomass with or without abiomass/coal blended compact aggregate made with unprocessedorganic-carbon-containing feedstock. First, the processed biomass/coalblended compact aggregate contains significantly less salt than thatproduced from current processes that use similar unprocessedorganic-carbon-containing feedstock. The salt in the processedorganic-carbon-containing feedstock and thus in the resulting processedbiomass is reduced by at least 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of the salt content of theunprocessed organic-carbon-containing feedstock. The reduction in saltcontent is based on a comparison between processedorganic-carbon-containing feedstock on a dry basis and unprocessedorganic-carbon-containing feedstock on a dry basis. After the subsequentheating step to convert processed organic-carbon-containing feedstockinto processed biochar, the salt content is not further changed but thetotal solids on a dry basis are reduced by some percentage because someof the solids of the processed organic-carbon-containing feedstock arebeing converted into liquid or gas phases. Another effect of the saltreduction between the processed and unprocessedorganic-carbon-containing feedstock is that the fixed carbon of theresulting processed biochar of some embodiments is higher and the ashcontent is lower because there is less salt that forms ash duringsubsequent combustion of the biochar in a boiler. In addition, theadverse effect of salt in the boiler is reduced, wear is slower, andmaintenance cleaning of the equipment is less often and less arduous.

Second, the processed biomass with coal or with processed biomass/coalblended compact aggregate have a high energy density, approaching thatof the high energy coal component of at least 21 MMBTU/ton (24 GJ/MT).They also have similar or higher energy densities than that of lowenergy coal. The energy density of the processed biomass is at least 17MMBTU/ton (20 GJ/MT) with some embodiments being at least 21 MMBTU/ton(24 GJ/MT). Some embodiments have an energy density of at least 23MMBTU/ton (27 GJ/MT), some at least 26 MMBTU/ton (30 GJ/MT), some atleast 28 MMBTU/ton (33 GJ/MT), some at least 30 MMBTU/ton (35 GJ/MT),and some at least 31 MMBTU/ton (36 GJ/MT). In contrast, the energydensity of unprocessed biochar made with oxygen deficient heating ofunprocessed organic-carbon-containing feedstock is often between 10MMBTU/ton (12 GJ/MT) and 12 MMBTU/ton (14 GJ/MT).

Third, the processed biomass with coal or with processed biomass/coalblended compact aggregate can contain significantly less pollutantsassociated with coal by itself depending on the content of the processedbiomass used in the aggregate. This processed aggregate contains littleif any pollutants normally associated with coal. These pollutantsassociated with coal include, for example, mercury (neurotoxin), arsenic(carcinogen), and SxOy when the coal is combusted. Processed biomasscontains less than 0.1 wt % of any one of the above impurities, someembodiments contain less than 0.01 wt %, some less than 0.001 wt %, someless than 0.0001 wt %.

Fourth, in embodiments with processed biomass/coal blended compactaggregate replacing the coal in the coal steam, higher levels ofprocessed biomass can be blended with coal fines to permit a variety ofscenarios depending on what is desired. Because of the lower saltcontent and higher energy density of the processed biomass, coal biomassblends that contain at least 10 wt % biomass are now possible withenergy densities approximating or exceeding that of the coal componentand with substantially reduced levels of intracellular salt from thebiomass component. In some embodiments, the biomass content is at least20 wt %, in some at least 30 wt %, in some at least 40 wt %, in some atleast 50 wt %, in some at least 60 wt %, in some at least 70 wt %, andin some at least 80 wt %. Similarly, because of the low salt content andhigh energy density of the processed biomass, it is now possible tosafety transport coal fines in blends that contain at least 10 wt %coal. In some embodiments, the coal content is at least 20 wt %, in someat least 30 wt %, in some at least 40 wt %, in some at least 50 wt %, insome at least 60 wt %, in some at least 70 wt %, and in some at least 80wt %. This permits coal fines to be safely used in commerce as a fuelsource for such processes as heating boilers. It also permits asignificant portion of the blend to be renewable solid fuel without asacrifice of cleanliness of materials or energy density associated withcurrent blends of unprocessed biomass and coal.

The processed biomass/coal blended compact aggregate in place of coalhas several improved characteristics when compared to a biomass/coalblended compact aggregate made with unprocessedorganic-carbon-containing feedstock. First, the processed biomass/coalblended compact aggregate contains significantly less salt than thatproduced from current processes that use similar unprocessedorganic-carbon-containing feedstock. The salt in the processedorganic-carbon-containing feedstock and thus in the resulting processedbiochar is reduced by at least 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of the salt content of theunprocessed organic-carbon-containing feedstock. As a result, the fixedcarbon of the resulting processed biochar is higher and the ash contentis lower because there is less salt that forms ash during combustion.Also, the adverse effect of salt in the boiler is reduced, wear isslower, and maintenance cleaning of the equipment is less often and lessarduous.

Second, the processed biomass/coal blended compact aggregate has anenergy density that typically approaches that of the low energy coalcomponent of less than 21 MMBTU/ton (24 GJ/MT) or exceeds it dependingon the specific demands of a particular application or use. The energydensity of the processed biomass is at least 17 MMBTU/ton (20 GJ/MT)with some embodiments being at least 21 MMBTU/ton (24 GJ/MT). Someembodiments have an energy density of at least 23 MMBTU/ton (27 GJ/MT),some at least 26 MMBTU/ton (30 GJ/MT), some at least 28 MMBTU/ton (33GJ/MT), some at least 30 MMBTU/ton (35 GJ/MT), and some at least 31MMBTU/ton (36 GJ/MT). In contrast, the energy density of unprocessedbiomass made with oxygen deficient heating of unprocessedorganic-carbon-containing feedstock is often between 10 MMBTU/ton (12GJ/MT) and 12 MMBTU/ton (14 GJ/MT) and generally under 26 MMBTU/ton (30GJ/MT)—and still have the retained salt from the unprocessed biomass.

Third, the processed biomass/coal blended compact aggregate can containsignificantly less amounts of pollutants associated with coal by itselfdepending on the content of the processed biomass used in the aggregate.This processed aggregate contains little if any pollutants normallyassociated with coal. These pollutants associated with coal include, forexample, mercury (neurotoxin), arsenic (carcinogen), and SxOy when thecoal is combusted. Processed biomass contains less than 0.1 wt % of anyone of the above impurities, some embodiments contain less than 0.01 wt%, some less than 0.001 wt %, some less than 0.0001 wt %.

Fourth, the processed biomass/coal blended compact aggregate containseven less if any decrease in energy density over the coal if a processedbiomass binder is used to assist formation of pellets. The processedbiomass binder comprises cleaned micro particles of processedorganic-carbon-containing feedstock and lignin effluent that is from thebeneficiation sub-system and has an energy density in a dry form of over17 MMBTU/ton (20 GJ/MT), in some cases of at least 19 MMBTU/ton (22GJ/MT), in some cases of at least 21 MMBTU/ton (24 GJ/MT), and in somecases of at least 23 MMBTU/ton (27 GJ/MT).

In some embodiments of the inventions, organic-carbon-containingfeedstock used to make the processed biomass/coal blended compactaggregate of the invention can contain mixtures of more than onerenewable feedstock when the processed organic-carbon-containingfeedstock is made to have substantially uniform energy densitiesregardless of the type of organic-carbon-containing feedstock used.

Unprocessed Organic-Carbon-Containing Feedstock

Cellulose bundles, interwoven by hemicellulose and lignin polymerstrands, are the stuff that makes plants strong and proficient inretaining moisture. Cellulose has evolved over several billion years toresist being broken down by heat, chemicals, or microbes. In a plantcell wall, the bundles of cellulose molecules in the microfibrilsprovide the wall with tensile strength. The tensile strength ofcellulose microfibrils is as high as 110 kg/mm², or approximately 2.5times that of the strongest steel in laboratory conditions. Whencellulose is wetted, as in the cell walls, its tensile strength declinesrapidly, significantly reducing its ability to provide mechanicalsupport. But in biological systems, the cellulose skeleton is embeddedin a matrix of pectin, hemicellulose, and lignin that act aswaterproofing and strengthening material. That makes it difficult toproduce fuels from renewable cellulose-containing biomass fast enough,cheap enough, or on a large enough scale to make economical sense. Asused herein, organic-carbon-containing material means renewableplant-containing material that can be renewed in less than 50 years andincludes plant material such as, for example herbaceous materials suchas grasses, energy crops, and agricultural plant waste; woody materialssuch as tree parts, other woody waste, and discarded items made fromwood such as broken furniture and railroad ties; and animal materialcontaining undigested plant cells such as animal manure.Organic-carbon-containing material that is used as a feedstock in aprocess is called an organic-carbon-containing feedstock

Unprocessed organic-carbon-containing material, also referred to asrenewable biomass, encompasses a wide array of organic materials asstated above. It is estimated that the U.S. alone generates billions oftons of organic-carbon-containing material annually. As used in thisdocument, beneficiated organic-carbon-containing feedstock is processedorganic-carbon-containing feedstock where the moisture content has beenreduced, a significant amount of dissolved salts have been removed, andthe energy density of the material has been increased. This processedfeedstock can be used as input for processes that make severalenergy-producing products, including, for example, liquid hydrocarbonfuels, solid fuel to supplant coal, and synthetic natural gas.

As everyone in the business of making organic-carbon-containingfeedstock is reminded, the energy balance is the metric that mattersmost. The amount of energy used to beneficiate organic-carbon-containingfeedstock and, thus, the cost of that energy must be substantiallyoffset by the overall improvement realized by the beneficiation processin the first place. For example, committing 1000 BTU to improve the heatcontent of the processed organic-carbon-containing feedstock by 1000BTU, all other things being equal, does not make economic sense unlessthe concurrent removal of a significant amount of the water-soluble saltrenders previously unusable organic-carbon-containing feedstock usableas a fuel substitute for some processes such as boilers.

As used herein, organic-carbon-containing feedstock comprises freewater, intercellular water, intracellular water, intracellularwater-salts, and at least some plant cells comprising cell walls thatinclude lignin, hemicellulose, and cellulosic microfibrils withinfibrils. In some embodiments, the water-soluble salt content of theunprocessed organic-carbon-containing feedstock is at least 4000 mg/kgon a dry basis. In other embodiments the salt content may be more than1000 mg/kg, 2000 mg/kg, or 3000 mg/kg. The content is largely dependenton the soil where the organic-carbon-containing material is grown.Regions that are land rich and more able to allow land use for growingenergy crops in commercial quantities often have alkaline soils thatresult in organic-carbon-containing feedstock with water-soluble saltcontent of over 4000 mg/kg.

Water-soluble salts are undesirable in processes that useorganic-carbon-containing feedstock to create fuels. The salt tends toshorten the operating life of equipment through corrosion, fouling, orslagging when combusted. Some boilers have standards that limit theconcentration of salt in fuels to less than 1500 mg/kg. This is to finda balance between availability of fuel for the boilers and expense offrequency of cleaning the equipment and replacing parts. If economical,less salt would be preferred. In fact, salt reduction throughbeneficiation is an enabling technology for the use of salt-ladenbiomass (e.g. hogged fuels, mesquite, and pinyon-junipers) in boilers.Salt also frequently poisons catalysts and inhibits bacteria or enzymeuse in processes used for creating beneficial fuels. While some saltconcentration is tolerated, desirably the salt levels should be as lowas economically feasible.

The water-soluble salt and various forms of water are located in variousregions in plant cells. As used herein, plant cells are composed of cellwalls that include microfibril bundles within fibrils and includeintracellular water and intracellular water-soluble salt. FIG. 1 is adiagram of a typical plant cell with an exploded view of a region of itscell wall showing the arrangement of fibrils, microfibrils, andcellulose in the cell wall. A plant cell (100) is shown with a sectionof cell wall (120) magnified to show a fibril (130). Each fibril iscomposed of microfibrils (140) that include strands of cellulose (150).The strands of cellulose pose some degree of ordering and hencecrystallinity.

Plant cells have a primary cell wall and a secondary cell wall. Thesecondary cell wall varies in thickness with type of plant and providesmost of the strength of plant material. FIG. 2 is a diagram of aperspective side view of a part of two fibrils bundled together in asecondary plant cell wall showing the fibrils containing microfibrilsand connected by strands of hemicellulose, and lignin. The section ofplant cell wall (200) is composed of many fibrils (210). Each fibril 210includes a sheath (220) surrounding an aggregate of cellulosicmicrofibrils (230). Fibrils 210 are bound together by interwoven strandsof hemicellulose (240) and lignin (250). In order to remove theintracellular water and intracellular water-soluble salt, sections ofcell wall 200 must be punctured by at least one of unbundling thefibrils from the network of strands of hemicellulose 240 and lignin 250,decrystallizing part of the strands, or depolymerizing part of thestrands.

The plant cells are separated from each other by intercellular water. Anaggregate of plant cells are grouped together in plant fibers, each witha wall of cellulose that is wet on its outside with free water alsoknown as surface moisture. The amount of water distributed within aspecific organic-carbon-containing feedstock varies with the material.As an example, water is distributed in fresh bagasse from herbaceousplants as follows: about 50 wt % intracellular water, about 30 wt %intercellular water, and about 20 wt % free water. Bagasse is thefibrous matter that remains after sugarcane or sorghum stalks arecrushed to extract their juice.

FIG. 3 is diagram of a cross-sectional view of a fiber section ofbagasse showing where water and water-soluble salts reside inside andoutside plant cells. A fiber with an aggregate of plant cells (300) isshown with surface moisture (310) on the outer cellulosic wall (320).Within fiber 300 lays individual plant cells (330) separated byintercellular water (340). Within each individual plant cell 330 laysintracellular water (350) and intracellular water-soluble salt (360).

Conventional methods to beneficiate organic-carbon-containing feedstockinclude thermal processes, mechanical processes, and physiochemicalprocesses. Thermal methods include heat treatments that involvepyrolysis and torrefaction. The thermal methods do not effectivelyremove entrained salts and only serve to concentrate them. Thus thermalprocesses are not acceptable for the creation of many energy creatingproducts such as organic-carbon-containing feedstock used as a fuelsubstitute to the likes of coal and petroleum. Additionally, allconventional thermal methods are energy intensive, leading to anunfavorable overall energy balance, and thus economically limiting inthe commercial use of organic-carbon-containing feedstock as a renewablesource of energy.

The mechanical method, also called pressure extrusion or densification,can be divided into two discrete processes where water and water-solublesalts are forcibly extruded from the organic-carbon-containing material.These two processes are intercellular and intracellular extrusion. Theextrusion of intercellular water and intercellular water-soluble saltoccurs at a moderate pressure, depending upon the freshness of theorganic-carbon-containing material, particle size, initial moisturecontent, and the variety of organic-carbon-containing material.Appropriately sized particles of freshly cut herbaceousorganic-carbon-containing feedstock with moisture content between 50 wt% and 60 wt % will begin extruding intercellular moisture at pressuresas low as 1,000 psi and will continue until excessive pressure forcesthe moisture into the plant cells (essentially becoming intracellularmoisture).

As the densification proceeds, higher pressures, and hence higher energycosts, are required to try to extrude intracellular water andintracellular water-soluble salt. However, stiff cell walls provide thebiomass material with mechanical strength and are able to withstand highpressures without loss of structural integrity. In addition, theformation of impermeable felts more prevalent in weaker cell walledherbaceous material has been observed during compaction of differentherbaceous biomass materials above a threshold pressure. This method isenergy intensive. In addition, it can only remove up to 50 percent ofthe water-soluble salts on a dry basis (the intracellular salt remains)and is unable to reduce the remaining total water content to below 30 wtpercent.

The felts are formed when long fibers form a weave and are boundtogether by very small particles of pith. Pith is a tissue found inplants and is composed of soft, spongy parenchyma cells, which store andtransport water-soluble nutrients throughout the plant. Pith particlescan hold 50 times their own weight in water. As the compression forcesexerted during the compaction force water into the forming felts, theentrained pith particles collect moisture up to their capacity. As aresult, the moisture content of any felt can approach 90%. When feltsform during compaction, regardless of the forces applied, the overallmoisture content of the compacted biomass will be substantially higherthan it would have been otherwise had the felt not formed. The feltblocks the exit ports of the compaction device as well as segmentsperpendicular to the applied force, and the water is blocked fromexpulsion from the compaction device. The felt also blocks water passingthrough the plant fibers and plant cells resulting in some water passingback through cell wall pores into some plant cells. In addition, it canonly remove up to 50 percent of the water-soluble salts on a dry basisand is unable to reduce more than the water content to below 30 wtpercent.

The physiochemical method involves a chemical pretreatment oforganic-carbon-containing feedstock and a pressure decompression priorto compaction to substantially improve the quality of densified biomasswhile also reducing the amount of energy required during compaction toachieve the desired bulk density. Chemically, biomass comprises mostlycellulose, hemicellulose, and lignin located in the secondary cell wallof relevant plant materials. The strands of cellulose and hemicelluloseare cross-linked by lignin, forming a lignin-carbohydrate complex (LCC).The LCC produces the hydrophobic barrier to the elimination ofintracellular water. In addition to the paper pulping process thatsolublizes too much of the organic-carbon-containing material,conventional pre-treatments include acid hydrolysis, steam explosion,AFEX, alkaline wet oxidation, and ozone treatment. All of theseprocesses, if not carefully engineered, can be can be expensive on acost per product weight basis and are not designed to remove more than25% water-soluble salt on a dry weight basis.

In addition, the energy density generally obtainable from anorganic-carbon-containing material is dependent on its type, i.e.,herbaceous, soft woody, and hard woody. Also mixing types in subsequentuses such as fuel for power plants is generally undesirable because theenergy density of current processed organic-carbon-containing feedstockvaries greatly with type of plant material.

As stated above, plant material can be further subdivided in to threesub classes, herbaceous, soft woody and hard woody, each with particularwater retention mechanisms. All plant cells have a primary cell wall anda secondary cell wall. As stated earlier, the strength of the materialcomes mostly from the secondary cell wall, not the primary one. Thesecondary cell wall for even soft woody materials is thicker than forherbaceous material.

Herbaceous plants are relatively weak-walled plants, include corn, andhave a maximum height of less than about 10 to 15 feet (about 3 to 5meters (M)). While all plants contain pith particles, herbaceous plantsretain most of their moisture through a high concentration of pithparticles within the plant cells that hold water like balloons becausethese plants have relatively weak cell walls. Pressure merely deformsthe balloons and does not cause the plant to give up its water.Herbaceous plants have about 50% of their water as intracellular waterand have an energy density of unprocessed material at about 5.2 millionBTUs per ton (MMBTU/ton) or 6 Gigajoules per metric ton (GJ/MT).

Soft woody materials are more sturdy plants than herbaceous plants. Softwoody materials include pines and typically have a maximum height ofbetween 50 and 60 feet (about 15 and 18 M). Their plant cells havestiffer walls and thus need less pith particles to retain moisture. Softwoody materials have about 50% of their water as intracellular water andhave an energy density of about 13-14 MMBTU/ton (15-16 GJ/MT).

Hard woody materials are the most sturdy of plants, include oak, andtypically have a maximum height of between 60 and 90 feet (18 and 27 M).They have cellulosic plant cells with the thickest secondary cell walland thus need the least amount of pith particles to retain moisture.Hard woody materials have about 50% of their water as intracellularwater and have an energy density of about 15 MMBTU/ton (17 GJ/MT).

There is a need in the energy industry for a system and method to allowthe energy industry to use organic-carbon-containing material as acommercial alternative or adjunct fuel source. Much of the landavailable to grow renewable organic-carbon-containing material on acommercial scale also results in organic-carbon-containing material thathas a higher than desired content of water-soluble salt that typicallyis at levels of at least 4000 mg/kg. Forest products in the PacificNorthwest are often transported via intracoastal waterways, exposing thebiomass to salt from the ocean. Thus such a system and method must beable to remove sufficient levels of water-soluble salt to provide asuitable fuel substitute. As an example, boilers generally need saltcontents of less than 1500 mg/kg to avoid costly maintenance related tohigh salt in the fuel. In addition, the energy and resulting cost toremove sufficient water to achieve an acceptable energy density must below enough to make the organic-carbon-containing material feedstock asuitable alternative in processes to make coal or hydrocarbon fuelsubstitutes.

There is also a need for a process that can handle the various types ofplants and arrive at processed organic-carbon-containing feedstock withsimilar energy densities.

The invention disclosed does allow the energy industry to use processedorganic-carbon-containing material as a commercial alternative fuelsource. Some embodiments of the invention remove almost all of thechemical contamination, man-made or natural, and lower the total watercontent to levels in the range of 5 wt % to 15 wt %. This allows theindustries, such as the electric utility industry to blend theorganic-carbon-containing feedstock on a ratio of up to 50 wt %processed organic-carbon-containing feedstock to 50 wt % coal with asubstantial reduction in the amount of water-soluble salt and enjoy thesame MMBTU/ton (GJ/MT) efficiency as coal at coal competitive prices.Literature has described organic-carbon-containing feedstock to coalratios of up to 30%. A recent patent application publication, EP2580307A2, has described a ratio of up to 50% by mechanical compaction underheat, but there was no explicit reduction in water-soluble salt contentin the organic-carbon-containing feedstock. The invention disclosedherein explicitly comprises substantial water-soluble salt reductionthrough a reaction chamber with conditions tailored to each specificunprocessed organic-carbon-containing feedstock used. As discussedbelow, additional purposed rinse subsections and subsequent pressingalgorithms in the compaction section of the Reaction Chamber may bebeneficial to process organic-carbon-containing feedstock that has aparticularly high content of water-soluble salt so that it may be usedin a blend with coal that otherwise would be unavailable for burning ina coal boiler. This also includes, for example, hog fuel, mesquite, andEastern red cedar.

In addition, the invention disclosed does permit different types oforganic-carbon-containing feedstock to be processed, each at tailoredconditions, to result in processed outputs having preselected energydensities. In some embodiments of the invention, more than one type offeedstock with different energy densities that range from 5.2 to 14MMBTU/ton (6 to 16 GJ/MT) may be fed into the reaction chamber in seriesor through different reaction chambers in parallel. Because each type oforganic-carbon-containing feedstock is processed under preselectedtailored conditions, the resulting processed organic-carbon-containingfeedstock for some embodiments of the system of the invention can have asubstantially similar energy density. In some embodiments, the energydensity is about 17 MMBTU/ton (20 GJ/MT). In others it is about 18, 19,or 20 MMBTU/ton (21, 22, or 23 GJ/MT). This offers a tremendousadvantage for down-stream processes to be able to work with processedorganic-carbon-containing feedstock having similar energy densityregardless of the type used as well as substantially reducedwater-soluble content.

The process of the invention uses a beneficiation sub-system to createthe processed organic-carbon-containing feedstock that is a cleaneconomical material to be used for creating a satisfactory processedbiomass/coal blended compact aggregate from renewable biomass, anoptional heating sub-system, and a blending subsystem for converting theprocessed organic-carbon-containing feedstock and coal into theprocessed biomass/coal blended compact aggregate of the invention. Thefirst subsystem will now be discussed.

Beneficiation Sub-System

The beneficiation sub-system is used to make processedorganic-carbon-containing feedstock comprises at least three elements, atransmission device, at least one reaction chamber, and a collectiondevice. As used in this document, the beneficiation sub-system refers tothe system that is used to convert unprocessed organic-carbon-containingfeedstock into processed organic-carbon-containing feedstock.

The first element, the transmission device, is configured to convey intoa reaction chamber unprocessed organic-carbon-containing feedstockcomprising free water, intercellular water, intracellular water,intracellular water-soluble salt, and at least some plant cellscomprising cell walls that include lignin, hemicellulose, and cellulosicmicrofibrils within fibrils. The transmission device may be any that issuitable to convey solid unprocessed organic-carbon-containing feedstockinto the reaction chamber to obtain a consistent residence time of thefeedstock in the reaction chamber. The transmission devices include suchdevices at augers that are well known in the chemical industry.

Particle size of the unprocessed organic-carbon-containing feedstockshould be sufficiently small to permit a satisfactorily energy balanceas the unprocessed organic-carbon-containing feedstock is passed throughthe system to create processed organic-carbon-containing feedstock. Insome embodiments, the unprocessed organic-carbon-containing feedstockarrives at some nominal size. Herbaceous material such as, for example,energy crops and agricultural waste, should have a particle size wherethe longest dimension is less than 1 inch (2.5 cm). Preferably, mostwood and wood waste that is freshly cut should have a longest length ofless than 0.5 inches (1.3 cm). Preferably, old wood waste, especiallyresinous types of wood such as, for example pine, has a particle sizewith a longest dimension of less than 0.25 inches (about 0.6 cm) toobtain the optimum economic outcome, where throughput andenergy/chemical consumption are weighed together.

Some embodiments of the system may also include a mastication chamberbefore the reaction chamber. This mastication chamber is configured toreduce particle size of the organic-carbon-containing feedstock to lessthan 1 inch (2.5 cm) as the longest dimension. This allows theorganic-carbon-containing feedstock to arrive with particle sized havinga longest dimension larger than 1 inch (2.5 cm). In some embodiments,the longest dimension is less than 0.75 inches (1.9 cm), and in someless than 0.5 inches (1.3 cm).

Some embodiments of the system may also include a pretreatment chamberto remove contaminants that hinder creation of the passageways forintracellular water and water-soluble salts to pass from thecellulosic-fibril bundles. The chamber is configured to use for eachorganic-carbon-containing feedstock a particular set of conditionsincluding time duration, temperature profile, and chemical content ofpretreatment solution to at least initiate the dissolution ofcontaminates. The contaminants include resins, rosins, glue, andcreosote. The solid slurry, including any incipient felts, may becollected for use as binders in the processed organic-carbon-containingfeedstock that is the primary end product. Separated oils may becollected as a stand-alone product such as, for example, cedar oil.

The second element, the reaction chamber, includes at least one entrancepassageway, at least one exit passageway, and at least three sections, awet fibril disruption section, a vapor explosion section, and acompaction section. The first section, the wet fibril disruptionsection, is configured to break loose at least some of the lignin andhemicellulose between the cellulosic microfibrils in the fibril bundleto make at least some regions of cell wall more penetrable. This isaccomplished by at least one of several means. Theorganic-carbon-containing feedstock is mixed with appropriate chemicalsto permeate the plant fibrils and disrupt the lignin, hemicellulose, andLCC barriers. Additionally, the chemical treatment may also unbundle aportion of the cellulose fibrils and/or microfibrils, de-crystallizingand/or depolymerizing it. Preferably, the chemicals are tailored for thespecific organic-carbon-containing feedstock. In some embodiments, thechemical treatment comprises an aqueous solution containing a misciblevolatile gas. The miscible gas may include one or more of ammonia,bicarbonate/carbonate, or oxygen. Some embodiments may include aqueoussolutions of methanol, ammonium carbonate, or carbonic acid. The use ofmethanol, for example, may be desirable for organic-carbon-containingfeedstock having a higher woody content to dissolve resins contained inthe woody organic-carbon-containing feedstock to allow beneficiationchemicals better contact with the fibrils. After a predeterminedresidence time of mixing, the organic-carbon-containing feedstock may besteam driven, or conveyer by another means such as a piston, into thenext section of the reaction chamber. In some embodiments, processconditions should be chosen to not dissolve more than 25 wt % of thelignin or hemicellulose as these are important contributors to theenergy density of the processed organic-carbon-containing feedstock.Some embodiments of the system, depending on the specificorganic-carbon-containing feedstock used, may have temperatures of atleast 135° C., at least 165° C., or at least 180° C.; pressures of atleast 260 psig, at least 280 psig, at least 375 psig, or at least 640psig; and residence times of at least 15 minutes (min), 20 min, or 30min.

In some embodiments, micro-particles and lignin-rich fragments suspendedin the effluent is withdrawn from the reactive chamber for subsequentuse. The micro particles and lignin is cleansed of water-soluble saltsand other impurities as needed. The resulting slurry, often white, actsas a high energy biomass binder that is then mixed with the processedorganic-carbon-containing feedstock before the pelletizing step. Thisreduces the need for heat during pelletizing.

The second section, the vapor explosion section, is in communicationwith the wet fibril disruption section. It at least is configured tovolatilize plant fibril permeable fluid through rapid decompression topenetrate the more susceptible regions of the cell wall so as to createa porous organic-carbon-containing feedstock with cellulosic passagewaysfor intracellular water and water-soluble salts to pass from thecellulosic-fibril bundles. The organic-carbon-containing feedstock isisolated, heated, pressurized with a volatile fluid comprising steam.The applied volatile chemicals and steam penetrate into the plantfibrils within the vapor explosion section due to the high temperatureand pressure. After a predetermined residence time dictated by thespecific organic-carbon-containing feedstock used, pressure is releasedrapidly from the reaction chamber by opening a fast-opening valve intoan expansion chamber that may be designed to retain the gases, separatethem, and reuse at least some of them in the process for increasedenergy/chemical efficiency. Some embodiments may have no expansionchamber where retention of gasses is not desired. Some embodiments ofthe system, depending on the specific organic-carbon-containingfeedstock used, may have a specific pressure drop in psig of at least230, at least 250, at least 345, or at least 600; and explosivedurations of less than 500 milliseconds (ms), less than 300 ms, lessthan 200 ms, less than 100 ms, or less than 50 ms.

Some embodiments may include gas inlets into the wet fibril disruptionsection of the reaction chamber to deliver compressed air or othercompressed gas such as, for example, oxygen. After delivery to thedesired pressure, the inlet port would be closed and the heating for thereaction would proceed. Note that this could allow for at least one ofthree things: First, an increase in total pressure would make subsequentexplosion more powerful. Second, an increase in oxygen content wouldincrease the oxidation potential of the processedorganic-carbon-containing feedstock where desirable. Third, a provisionwould be provided for mixing of organic-carbon-containing feedstock,water, and potentially other chemicals such as, for example, organicsolvents, through bubbling action of gas through a perforated pipe atbottom of reaction chamber.

The net effect on the organic-carbon-containing feedstock of passingthrough the wet fibril disruption section and the vapor explosionsection is the disruption of fibril cell walls both physically throughpressure bursts and chemically through selective and minimal fibrilcellulosic delinking, cellulose depolymerization and/or cellulosedecrystallization. Chemical effects, such as hydrolysis of thecellulose, lignin, and hemicellulose also can occur. The resultingorganic-carbon-containing feedstock particles exhibit an increase in thesize and number of micropores in their fibrils and cell walls, and thusan increased surface area. The now porous organic-carbon-containingfeedstock is expelled from the vapor explosion section into the nextsection.

The third section, the compaction section is in communication with thevapor explosion section. The compression section at least is configuredto compress the porous organic-carbon-containing feedstock betweenpressure plates configured to minimize formation of felt that wouldclose the reaction chamber exit passageway made to permit escape ofintracellular and intercellular water, and intracellular andintercellular soluble salts. In this section, the principle processconditions for each organic-carbon-containing feedstock is the presenceor absence of a raised pattern on the pressure plate, the starting watercontent, the processed water content, and final water content. Thecompaction section of the system of the invention requires a raisedpatterned surface on the pressure plates for feedstock comprisingherbaceous plant material feedstock. However, the section may or may notrequire the raised pattern surface for processing soft woody or hardwoody plant material feedstock depending on the specific material usedand its freshness from harvest. Some embodiments of the system,depending on the specific organic-carbon-containing feedstock used, mayhave a starting water contents ranging from 70 to 80 wt %, from 45 to 55wt % or from 40 to 50 wt %; and processed water content of from 4 to 15wt % depending on actual targets desired.

The third element, the collection device, is in communication with thereaction chamber. The collection chamber at least is configured toseparate non-fuel components from fuel components and to create aprocessed organic-carbon-containing feedstock. This feedstock has awater content of less than 20 wt % and a water-soluble salt content thatis decreased by at least 60% on a dry basis. Some embodiments have thewater content less than 20 wt % after allowing for surface moisture toair dry. Some embodiments have a processed organic-carbon-containingfeedstock that has a water content of less than 15 wt %. Otherembodiments have processed organic-carbon-containing feedstock that hasa water content of less than 12 wt %, less than 10 wt %, less than 8 wt%, or less than 5 wt %. Some embodiments have a water-soluble saltcontent that is decreased by at least 65% on a dry basis. Otherembodiments have a water-soluble salt content that is decreased by atleast 70% on a dry basis, 75% on a dry basis, at least 80% on a drybasis, at least 85% on a dry basis, at least 90% on a dry basis, or atleast 95% on a dry basis.

Some embodiments of the system may further include at least one rinsingsubsection. This subsection is configured to flush at least some of thewater-soluble salt from the porous organic-carbon-containing feedstockbefore it is passed to the compaction section. In some embodiments wherethe salt content is particularly high, such as brine-soaked hog fuel(wood chips, shavings, or residue from sawmills or grinding machine usedto create it and also known as “hammer hogs”), the system is configuredto have more than one rinsing subsection followed by another compactionsection. The separated water, complete with dissolved water solublesalts, may be collected and treated for release into the surroundingenvironment or even reused in the field that is used to grow therenewable organic-carbon-containing feedstock. The salts in this waterare likely to include constituents purposefully added to the crops suchas fertilizer and pesticides.

The beneficiation sub-system of the invention can better be understoodthrough depiction of several figures. FIG. 4 is a diagram of a side viewof an embodiment of a reaction chamber in communication with anexpansion chamber to retain gasses emitted from the decompressedcarbon-containing feedstock. A reaction chamber (400) is shown with awet fibril disruption section (410). Solvent (412) and unprocessedorganic-carbon-containing feedstock (414) that has been chipped to lessthan 0.5 inches (1.3 cm) are fed in to wet fibril disruption section 410through valves (416) and (418), respectively to become prepared for thenext section. The pretreated organic-carbon-containing feedstock is thenpassed to a vapor explosion section (420) through a valve (422). Valvesare used between chambers and to input materials to allow for attainmentof specified targeted conditions in each chamber. Volatile expansionfluid, such as water, or water based volatile mixtures, are fed in tovapor expansion chamber 420 through a valve (424). The gas released fromthe porous organic-carbon-containing feedstock created duringdecompression is fed through a fast release valve (428) into anexpansion chamber (not shown) to retain the gas for possible reuse. Thecompaction section (430) received the porous organic-carbon-containingfeedstock through a valve (432) where the water and water-soluble saltare substantially removed from porous organic-carbon-containingfeedstock and it is now processed organic-carbon-containing feedstock.

As stated above, the pressure plates in the compaction section areconfigured to minimize felt formation. Felt is an agglomeration ofinterwoven fibers that interweave to form an impermeable barrier thatstops water and water-soluble salts entrained in that water from passingthrough the exit ports of the compaction section. Additionally, any pithparticles that survived the beneficiation process in the first twosections of reaction chamber can be entrained in the felt to absorbwater, thereby preventing expulsion of the water during pressing.Therefore, felt formation traps a significant fraction of the water andsalts from being extruded from the interior of biomass being compressed.FIGS. 5A, 5B, and 5C show embodiments of pressure plates and how theywork to minimize felt formation so that water and water-soluble saltsare able to flow freely from the compaction section. FIG. 5A is adiagram of the front views of various embodiments of pressure plates.Shown is the surface of the pressure plate that is pressed against thedownstream flow of porous organic-carbon-containing feedstock. FIG. 5Bis a perspective view of a close-up of one embodiment of a pressureplate shown in FIG. 5A. FIG. 5C is a diagram showing the cross-sectionalview down the center of a pressure plate with force vectors and feltexposed to the force vectors. The upstream beneficiation process in thefirst two sections of the reaction chamber has severely weakened thefibers in the biomass, thereby also contributing to the minimization offelt formation.

Some embodiments achieve the processed organic-carbon-containingfeedstock water content and water-soluble salt reduction overunprocessed organic-carbon-containing feedstock with a cost that is lessthan 60% that of the cost per weight of processedorganic-carbon-containing feedstock from known mechanical, knownphysiochemical, or known thermal processes. In these embodiments, thereaction chamber is configured to operate at conditions tailored foreach unprocessed organic-carbon-containing feedstock and the system isfurther engineered to re-capture and reuse heat to minimize the energyconsumed to lead to a particular set of processedorganic-carbon-containing feedstock properties. The reaction chambersections are further configured as follows. The wet fibril disruptionsection is further configured to use fibril disruption conditionstailored for each organic-carbon-containing feedstock and that compriseat least a solvent medium, time duration, temperature profile, andpressure profile for each organic-carbon-containing feedstock. Thesecond section, the vapor explosion section, is configured to useexplosion conditions tailored for each organic-carbon-containingfeedstock and that comprise at least pressure drop, temperature profile,and explosion duration to form volatile plant fibril permeable fluidexplosions within the plant cells. The third section, the compactionsection, is configured to use compaction conditions tailored for eachorganic-carbon-containing feedstock and pressure, pressure plateconfiguration, residence time, and pressure versus time profile.

The importance of tailoring process conditions to eachorganic-carbon-containing feedstock is illustrated by the followingdiscussion on the viscoelastic/viscoplastic properties of plant fibrils.Besides the differences among plants in their cell wall configuration,depending on whether they are herbaceous, soft woody or hard woody,plants demonstrate to a varying degree of some interesting physicalproperties. Organic-carbon-containing material demonstrates both elasticand plastic properties, with a degree that depends on both the specificvariety of plant and its condition such as, for example, whether it isfresh or old. The physics that governs the elastic/plastic relationshipof viscoelastic/viscoplastic materials is quite complex. Unlike purelyelastic substances, a viscoelastic substance has an elastic componentand a viscous component. Similarly, a viscoplastic material has aplastic component and a viscous component. The speed of pressing aviscoelastic substance gives the substance a strain rate dependence onthe time until the material's elastic limit is reached. Once the elasticlimit is exceeded, the fibrils in the material begin to suffer plastic,i.e., permanent, deformation. FIG. 6A is a graphical illustration of thetypical stress-strain curve for lignocellulosic fibril. Since viscosity,a critical aspect of both viscoelasticity and viscoelasticity, is theresistance to thermally activated deformation, a viscous material willlose energy throughout a compaction cycle. Plastic deformation alsoresults in lost energy as observed by the fibril's failure to restoreitself to its original shape. Importantly,viscoelasticity/viscoplasticity results in a molecular rearrangement.When a stress is applied to a viscoelastic material, such as aparticular organic-carbon-containing feedstock, some of its constituentfibrils and entrained water molecules change position and, while doingso, lose energy in the form of heat because of friction. It is importantto stress that the energy that the material loses to its environment isenergy that is received from the compactor and thus energy that isexpended by the process. When additional stress is applied beyond thematerial's elastic limit, the fibrils themselves change shape and notjust position. A “visco”-substance will, by definition, lose energy toits environment in the form of heat.

An example of how the compaction cycle is optimized for oneorganic-carbon-containing feedstock to minimize energy consumption toachieve targeted product values follows. Through experimentation, abalance is made between energy consumed and energy density achieved.FIG. 6B is a graphical illustration of pressure and energy required todecrease the water content and increase the bulk density of typicalorganic-carbon-containing feedstock. Bulk density is related to watercontent with higher bulk density equaling lower water content. Theorganic-carbon-containing feedstock compaction process will strike anoptimum balance between cycle time affecting productivity, net moistureextrusion together with associated water-soluble salts and minerals,permanent bulk density improvement net of the rebound effect due toviscoelastic/viscoplastic properties of the feedstock, and energyconsumption.

FIG. 6C is an experimentally derived graphical illustration of theenergy demand multiplier needed to achieve a bulk density multiplier.The compaction cycle can be further optimized for each variety andcondition of organic-carbon-containing feedstock to achieve the desiredresults at lesser pressures, i.e., energy consumption, by incorporatingbrief pauses into the cycle. FIG. 6D is a graphical illustration of anexample of a pressure cycle for decreasing water content in anorganic-carbon-containing feedstock with an embodiment of the inventiontailored to a specific organic-carbon-containing feedstock.

In a similar manner, energy consumption can be optimized during the wetfibril disruption and the vapor explosion parts of the system. Chemicalpretreatment prior to compaction will further improve the quality of theproduct and also reduce the net energy consumption. For comparisonpurposes, the pressure applied to achieve a bulk density multiplier of“10” in FIG. 6C was on the order of 10,000 psi, requiring uneconomicallyhigh cost of capital equipment and unsatisfactorily high energy costs todecompress the organic-carbon-containing feedstock.

FIG. 7 is a table illustrating the estimated energy consumption neededto remove at least 75 wt % water-soluble salts fromorganic-carbon-containing feedstock and reduce water content from 50 wt% to 12 wt % with embodiments of the invention compared with knownprocesses. Waste wood with a starting water content of 50 wt % was usedin the estimate to illustrate a side-by-side comparison of threeembodiments of the invention with known mechanical, physiochemical, andthermal processes. The embodiments of the system selected use a fibrilswelling fluid comprising water, water with methanol, water with carbondioxide bubbled into it produces carbonic acid H₂CO₃. As seen in thetable, and discussed above, known mechanical processes are unable toreduce the water content to 12 wt %, known physiochemical processes areunable to reduce water-soluble salt content by over 25 wt %, and knownthermal processes are unable to remove any water-soluble salt. The totalenergy requirement per ton for the three embodiments of the invention,that using methanol and water, carbon dioxide and water, and just wateris 0.28 MMBTU/ton (0.31 3, 0.31 MMBTU/ton (0.36 GJ/MT), and 0.42MMBTU/ton (0.49 GJ/MT), respectively. This is compared to 0.41 MMBTU/ton(0.48 GJ/MT), 0.90 MMBTU/ton (1.05 GJ/MT), and 0.78 MMBTU/ton (0.91GJ/MT) for known mechanical, known physiochemical, and known thermalprocesses, respectively. Thus, the estimated energy requirements toremove water down to a content of less than 20 wt % and water-solublesalt by 75 wt % on a dry basis for embodiments of the system inventionto less than 60% that of known physiochemical and known thermalprocesses that are able to remove that much water and water-solublesalt. In addition, the system invention is able to remove far morewater-soluble salt than is possible with known physiochemical and knownthermal processes that are able to remove that much water.

Multiple reaction chambers may be used in parallel to simulate acontinuous process. FIG. 8 is a diagram of a side view of an embodimentof a beneficiation sub-system having four reaction chambers in parallel,a pretreatment chamber, and a vapor condensation chamber. A system (800)includes an input section (802) that delivers organic-carbon-containingfeedstock to system 800. Feedstock passes through a mastication chamber(804) prior to entry into an organic-carbon-containing feedstock hopper((806) from where is passes on to a pretreatment chamber (810).Contaminants are removed through a liquid effluent line (812) to aseparation device (814) such as a centrifuge and having an exit stream(815) for contaminants, a liquid discharge line (816) that moves liquidto a filter media tank (818) and beyond for reuse, and a solid dischargeline (820) that places solids back into the porousorganic-carbon-containing feedstock. Liquid from the filter medial tank818 is passed to a remix tank (822) and then to a heat exchanger (824)or to a second remix tank (830) and to pretreatment chamber 810. Theorganic-carbon-containing feedstock passes onto one of four reactionchambers (840) comprising three sections. The first section of eachreaction chamber, a wet fibril disruption section (842), is followed bythe second section, a vapor explosion section (844), and a rinsingsubsection (846). A high pressure steam boiler (848) is fed by a makeupwater line (850) and the heat source (not shown) is additionally heatedwith fuel from a combustion air line (852). The main steam line (854)supplies steam to pretreatment chamber 810 and through high pressuresteam lines (856) to reaction chambers 840. A vapor expansion chamber(860) containing a vapor condensation loop is attached to each vaporexplosion sections with vapor explosion manifolds (862) to condense thegas. A volatile organic components and solvent vapor line (864) passesthe vapor back to a combustion air line (852) and the vapors in vaporexpansion chamber 860 are passes through a heat exchanger (870) tocapture heat for reuse in reaction chamber 840. The now porousorganic-carbon-containing feedstock now passes through the third sectionof reaction chamber 840, a compaction section (880). Liquid fluid passesthrough the liquid fluid exit passageway (884) back through fluidseparation device (814) and solid processed organic-carbon-containingfeedstock exits at (886).

Heating Sub-System

The optional heating sub-system is used to convert the processedorganic-carbon-containing feedstock to processed biochar for subsequentblending with coal. In its broadest understanding, the heatingsub-system comprises a reaction chamber configured to heat the processedorganic-carbon-containing feedstock in an oxygen deficient atmosphere.The heating sub-system comprises at least two forms, one anoxygen-deficient thermal sub-system and one a microwave sub-system.Others are possible as long as they provide heat in an oxygen deficientenvironment.

Oxygen-Deficient Thermal Sub-System

The oxygen-deficient thermal sub-system is used to convert the processedorganic-carbon-containing feedstock from the beneficiation sub-systeminto the clean porous processed biochar of the invention. In itsbroadest understanding, the oxygen-deficient thermal sub-systemcomprises a reaction chamber configured to heat processedorganic-carbon-containing feedstock in an atmosphere that contains lessthan 4 percent oxygen to a temperature sufficient to convert at leastsome processed organic-carbon-containing feedstock into processed biogasand processed biochar. In some embodiments, the atmosphere contains lessthan 3 percent oxygen and in some less than 2 percent oxygen. Thesub-system further comprises at least two aspects that are suitable forthe invention—a conventional pyrolysis oxygen-deficient thermal system,and a sublimation oxygen-deficient thermal sub-system.

Pyrolysis Oxygen-Deficient Thermal Sub-System

The common pyrolysis oxygen-deficient thermal sub-system producesbiochar, liquids, and gases from biomass by heating the biomass in alow/no oxygen environment. The absence of oxygen prevents combustion.The relative yield of products from pyrolysis varies with temperature.Temperatures of 400-500° C. (752-932° F.) produce more char, whiletemperatures above 700° C. (1,292° F.) favor the yield of liquid andgaseous fuel components. Pyrolysis occurs more quickly at the highertemperatures, typically requiring seconds instead of hours. Typicalyields are 60% bio-oil, 20% biochar, and 20% volatile gases. In thepresence of stoichiometric oxygen concentration, high temperaturepyrolysis is also known as gasification, and produces primarily syngas.By comparison, slow pyrolysis can produce substantially more char, onthe order of about 50%. The main benefit from the invention is that theresulting processed biochar made with processedorganic-carbon-containing feedstock has a water-soluble salt contentthat is reduced by at least 60 wt % from that of processed biochar madewith similar unprocessed organic-carbon-containing feedstock. In someembodiments, the water-soluble salt content is reduced by at least 65 wt%; in some at least 70 wt %; in some at least 80 wt %; in some at least85 wt %; at least some at least 90 wt %.

Sublimation Oxygen-Deficient Thermal Sub-System

Another oxygen-deficient thermal sub-system is sublimationoxygen-deficient thermal sub-system. Unlike the pyrolysis sub-system,the feedstock in the sublimation sub-system does not pass through aliquid phase and the products are only fuel gases and processed biochar.

The following description relates to approaches for processingorganic-carbon-containing feedstock into gaseous fuel and a processedbiochar fuel by a sublimation sub-system. The gaseous fuel is primarilymethane but also may include ethane, propane, and butane depending onthe nature of the organic-carbon-containing feedstock and the residencetimes employed during the sublimation process. Processed biochar fuel isthe solid carbon-based residue that is unable to be converted intogaseous fuel at a sublimation temperature. Alternatively, systemconditions may be adjusted to preferentially create more than theminimum processed biochar.

The sublimation sub-system is a high temperature sub-system configuredto convert a solid renewable biomass to a gaseous fuel and processedbiochar cleanly without passing through a liquid state, a passage thatcan result in many side reactions discussed above under gasification.The key to sublimation is to expose the solid to a high temperature inthe absence of free water and in a substantially oxygen free atmosphere.Under sublimation, the methane molecules and higher carbon groups suchas ethane, propane, and butane, are rejoined after being deconstructedfrom a carbon chain in the feedstock without breaking down to carbondioxide and water.

The processed biochar made in the sublimation sub-system has severaladvantages over that of the low water-soluble salt content of processedbiochar made in the pyrolysis sub-system discussed above. First, theprocessed biochar contains substantially no volatiles that may remain inthe pyrolysis sub-system. Volatiles present during depolymerizationtemperatures cause adverse reactions with carbons to form compoundsother than the desired processed biogas fuels and processed biochar ofthe invention. In addition, volatiles in the processed biochar reducethe heating content of the processed biochar by reducing the fixedcarbon in the resulting biochar. In the invention, the processed biocharis substantially devolatilized of condensable and non-condensable gasesand vapors. In some embodiments, the content of the gases and vapors isreduced by at least 95% by weight, in some embodiments it is reduced byat least 97% by weight, and in some it is reduced by at least 99% byweight versus char made from unprocessed organic-carbon-containingfeedstock in the pyrolysis sub-system with a volatile content of atleast 10% by weight. This is desirable in processed biochar applicationssuch as a coke alternative for steel making, gasification, andcombustion applications such as boilers because of the lowered contentof adverse corrosive compounds in the processed biochar of the inventionover that of processed biochar from the same feedstock but with thepyrolysis process.

Second, the processed biochar has a higher heating value than that ofprocessed biochar made with the same feedstock by the pyrolysis process.Because of better devolatization, there are fewer side reactions withthe volatiles and carbon during later use involving combustion of theprocessed biochar as fuel. Thus, a greater degree of fixed carbon canremain in the processed biochar of the invention than in the processedbiochar from similar feedstock in a pyrolysis sub-system. The fixedcarbon content in some embodiments is increased by at least 5% byweight, in some embodiments by at least 10% by weight, in someembodiments by at least 15% by weight, and in some embodiments by atleast 20% by weight. This increase in fixed carbon can result in anincrease in the heat content of some embodiments of the processedbiochar of the invention over that of processed biochar from the samefeedstock in a pyrolysis sub-system. Heat content is affected by thetype of organic-carbon-containing feedstock used and generally rangesfrom at least 20 MMBTU/ton (23 GJ/MT) to over 28 MMBTU/ton (33 GJ/MT)compared with less than 12 MMBTU/ton (14 GJ/MT) to less than 20MMBTU/ton (23 GJ/MT) for similar organic-carbon-containing feedstockmade in the pyrolysis sub-system. In some embodiments, the heat contentof the processed biochar is increased by at least 20% over processedbiochar by the pyrolysis sub-system, in some by at least 30%, in some byat least 40%, in some by at least 50%, in some by at least 60%, and bysome at least 70%. In addition, because of the reduced amount ofvolatiles, the processed biochar of the invention can burn withoutvisible smoke and with a smaller flame than seen with biochar made of asimilar feedstock in a pyrolysis sub-system. For some embodiments, theflame can be at least 5% less, for some embodiments at least 10% less,for some embodiments at least 15% less, for some embodiments at least20% less, for some embodiments at least 25% less, for some embodimentsat least 30% less, for some embodiments at least 35% less, and for someembodiments at least 40% less.

The sublimation system can be further illustrated by a horizontalsublimation system and a vertical sublimation system. Other orientationsmay be contemplated.

Horizontal Sublimation Oxygen-Deficient Thermal Sub-System

The horizontal sublimation oxygen-deficient thermal sub-system comprisesfour elements. The first is a hot box configured to be able to (1) heatfrom an ambient temperature to an operating sublimation temperature, (2)maintain an initial operating sublimation temperature and a finaloperating sublimation temperature that are stable within less than ±10°C., and (3) cool from operating sublimation temperatures to an ambienttemperature. All without leaking any oxygen into the hot box and havingat least one heat source in communication with the interior of the hotbox to supply heat as needed. The second element is at least onesubstantially horizontal reaction chamber largely located within the hotbox and having a surface. The reaction chamber is configured to heat theprocessed organic-carbon-containing feedstock without external catalystor additional water to an operating sublimation temperature in a timeframe that is short enough to sublime at least part of the processedorganic-carbon-containing feedstock without creating substantially anyliquid. The reaction chamber is also configured to heat from an ambienttemperature to an operating sublimation temperature, operate at asublimation temperature, and cool from an operating sublimationtemperature to an ambient temperature without leaking any product gasfuel into the surrounding hot box, and comprising an input end outsidethe hot box. The reaction chamber is further configured to receivecompressed feedstock through an input line and an output end outside thehot box and configured to discharge product gas fuel through a dischargeline and solid char fuel through an output line. The third element is afirst powered transport mechanism that is located within the reactionchamber and is configured to convey sublimation products of theprocessed organic-carbon-containing feedstock through the reactionchamber as the processed organic-carbon-containing feedstock istransformed into processed biogas and processed biochar. The fourthelement is a gas-tight element on both the input line and output lineand configured to prevent hot biogas from adversely escaping from thereaction chamber.

The overall process will now be discussed for using a substantiallyhorizontal sublimator to efficiently convert processed carbon-containingfeedstock to product biogas fuel and solid processed biochar fuel. Theprocess will be discussed briefly for an embodiment that needs processedorganic-carbon-containing feedstock preparation, drying and compression,and uses an apparatus with two reaction chambers and burners to deliversublimation heat. In some embodiments, the beneficiation sub-system isattached directly to horizontal sublimation oxygen-deficient thermalsub-system and the processed organic-carbon-containing feedstock needslittle if any preparation, drying, and compression. In some embodiments,the desired properties of the processed organic-carbon-containingfeedstock are such that at least some additional preparation, drying andor compression are desirable. Briefly, the sublimation sub-system ofthis embodiment of the invention is configured to be able to perform apreparation step, a drying step, a compression step, a sublimation step,and a separation step. Processed organic-carbon-containing feedstockpreparation will be dictated by the physical characteristics of theprocessed organic-carbon-containing feedstock being considered forprocessing/conversion such as its water content and physicalcharacteristics such as size and thickness. Size reduction ofcarbon-containing feedstock will enhance the compressibility of theprocessed organic-carbon-containing feedstock to allow for maximumthroughput in the reaction chamber. In some embodiments, sizes are of avolume that is less than the equivalent of a cube about 2 cm (about 0.75in) on a side with a length in any one direction of no more than about 5cm (about 2 in).

After the processed organic-carbon-containing feedstock is properlyprepared, it will then pass through a gas-tight element on an input lineinto a substantially horizontal drying chamber with an internal augerand be treated with recycled heat from the downstream process to driveoff as much free water as possible. Reducing the free water content willincrease the heat absorption by the processed organic-carbon-containingfeedstock and reduce the amount of oxygen present from the water insidethe sublimation reaction chamber and the finished product biogas fueland processed biochar. Reducing the free water and the oxygen willresult in less carbon dioxide and carbon monoxide in the product biogasfuel. Less CO2 and CO byproduct is desirable because it increases theenergy content of the processed biochar and the produced biogas.

After the drying chamber, the processed organic-carbon-containingfeedstock will pass into a compression chamber containing a compressionscrew that is designed to compress the carbon-containing feedstock tothe desired density. This compression further decreases any free waterremaining. It also removes entrained air in the processedorganic-carbon-containing feedstock that also will minimize the oxygenpresent in the sublimation reaction chamber. This dewatered, de-aired,and densified carbon-containing feedstock will enter the reactionchamber.

The compression chamber develops a feedstock plug at its exit thatenters the reaction chamber. This plug acts as a partial barrier or sealso a minimal amount of gases produced in the reaction chamber backflowand escape. The gas-tight element on the input line prevents the rest ofthe gases from escaping the system.

In the embodiment being discussed, the sublimation sub-system has aphysical plant that is a three dimensional, rectangular box with aninternal substantially horizontal reaction chamber running along thetop, a drop passage, and then a second substantially horizontal reactionchamber in the reverse direction of the top reaction chamber. Eachreaction chamber contains its own auger for transporting the feedstock,is continuous, and is completely sealed against the escape of any hotproduct gas fuel.

In this embodiment, burners are external to the heating box but attachedto it and will heat the space between the inside wall of the heating boxand the outside walls of the reaction chamber configuration so thatthere will be no intermingling of the heated transfer air heating theexternal surface of the reaction chamber and the contents of theprocessed organic-carbon-containing feedstock in the reaction chamberundergoing sublimation. All the internal surfaces of the heating box arelined with high thermal insulating material so as to minimize heat lossand minimize the internal reactor air space.

After the compression screw, the processed organic-carbon-containingfeedstock plug now enters the reaction chamber. The reaction chambercontaining an auger inside of it that may be inside of a tube vented toa head space above the tube but within the reaction chamber foraggregation of the gases that are generated. The auger propels androtates the processed organic-carbon-containing feedstock so that it isevenly exposed to the sidewalls of the tube or reaction chamber forefficient heat exchange and to ‘turn over’ the feedstock for evenheating. The reaction chamber is heated from the outside surface of thereaction chamber so the transfer heats the air and any combustionproducts from the burners do not get intermingled with the processedorganic-carbon-containing feedstock and/or product gas fuel or biogas.The reaction chamber is constructed to prevent the leaking out of anyhot gases.

The processed organic-carbon-containing feedstock is then augured downthe length of the reaction chamber. At the end of the reaction chamber,the carbon-containing feedstock drops down into a second auguredreaction chamber that is of the same design as the first reactor tube.The configuration of the three, chambers including the connectingpassage looks like a U rotated 90 degrees to the left.

The processed organic-carbon-containing feedstock has now been reducedto devolatilized carbon and volatile gases. The volatile gases arepassing and mixing with the hot carbon surfaces and reacting with it toform a dissociated hot product gas fuel. The residence time in both ofthe reaction chambers allows the volatile gases created during thesublimation to deconstruct down to several different structuresapproaching and including that of methane, and to move down the reactionchambers as product biogas fuel.

At the end of the second reactor chamber are two outlets. One outlet isfor the devolatized carbon to pass through a gas-tight mechanism and becollected as solid biochar fuel and the second outlet is for the productbiogas to be captured. The product gas is filtered and allowed to coolafter it exits the reaction chamber as the final product biogas fuel andthen stored.

More specifically, the apparatus aspect of the invention comprises asystem that includes a hot box, at least one reaction chamber, a firstpowered transport mechanism, and gas-tight elements. The hot box isconfigured to be able to heat from an ambient temperature to anoperating sublimation temperature, maintain an initial operatingsublimation temperature and a final operating sublimation temperaturethat are stable within less than ±10° C., and cool from operatingsublimation temperatures to an ambient temperature without leaking anyoxygen into the hot box and having at least one heat source incommunication with the interior of the hot box to supply heat as needed.

The temperature needed to sublime processed organic-carbon-containingfeedstock depends on the individual feedstock. If an operatingtemperature is too low, a liquid forms during the phase change fromsolid to gas with accompanying adverse reactions discussed above andassociated with gasification processes. If the temperature is too high,energy is wasted in an already endothermic reaction. Operatingsublimation temperatures are typically between 600° C. and 850° C. Morecommon low-density, processed, organic-carbon-containing feedstock haveoperating sublimation temperatures between 650° C. and 750° C.

For the above reasons, the operating temperature in the reaction chambershould be reasonably stable during operation of the apparatus. In someembodiments where the reaction chamber has a shorter length and theflowrate of the processed organic-carbon-containing feedstock issmaller, the operating temperature may be substantially constant withinless than ±10° C. In other embodiments having a longer residence timeand a larger processed organic-carbon-containing feedstock throughput,the reaction chamber may not be constant but rather forms a profilethrough the reaction chamber drops from the beginning to the end. Inthese embodiments, for energy efficiency reasons, the individualtemperatures of the temperature profile through the reaction chambershould be stable during operation within less than ±10° C.

The heat source must be able to heat the inside of the hot box to astable operating sublimation temperature and maintain that temperatureduring the operation of the apparatus. Heat sources may include any thatcan provide sufficient heat and include, for example, infrared sources,laser sources and combustion sources. Embodiments that use combustionsources have the additional advantage in that they can be fueled by someof the product biogas fuel such that they require no additional energyfrom external sources. Such embodiments may be self sufficient duringoperation with as little as 10 percent of the product gas fuel that iscreated in the apparatus. Some embodiments may be self-sufficient withas little as 7 percent and some with as little as 5 percent. This is dueto the high energy content of the product gas fuel and the variableamounts of energy needed to process different feedstock.

The at least one reaction chamber is substantially horizontal, locatedlargely within the hot box, has a surface, and is configured to heat theprocessed organic-carbon-containing feedstock without external catalystor additional water to an operating sublimation temperature in a timeframe that is short enough to sublime at least part of the processedorganic-carbon-containing feedstock without creating substantially anyliquid. Also, it is configured to heat from an ambient temperature to anoperating sublimation temperature, operate at a sublimation temperature,and cool from an operating sublimation temperature to an ambienttemperature without leaking any product biogas fuel into the surroundinghot box. Further, it comprises an input end outside the hot box andconfigured to receive compressed feedstock through an input line and anoutput end outside the hot box and configured to discharge productbiogas fuel through a pressure-isolation element and processed biocharfuel through an output line.

Sublimation is a reaction that deconstructs smaller gaseous hydrocarbonsfrom an organic-carbon-based feedstock and more particularly in the caseof the invention from a processed organic-carbon-based feedstock. In theinvention, the gas collects as a processed biogas fuel as it interactswith processed biochar solid fuel residue. Thus, there is no need forexpensive external catalysts and subsequent elaborate reformingoperations to create the processed biogas fuel. In addition, thesublimation of the invention is conducted in the presence of minimaloxygen since any oxygen reacts to cause non-fuel reaction products suchas carbon dioxide and carbon monoxide. Thus it is desirable to not usesuperheated steam in contact with the processedorganic-carbon-containing feedstock to achieve operating sublimationtemperature. Some oxygen that is interstitially locked in the cells maybe in the processed organic-carbon-containing feedstock. Also, someoxygen may enter the reaction chamber because of potentially incompletedrying when that drying step is desired. Both of these sources ofpotential oxygen sources should be mitigated by the beneficiationpre-processing: cell walls broken exposing interstitial water and oxygento expulsion and also a good pre-drying process. Thus, these sources ofoxygen comprise a small portion and contribute to less than 5 percent ofthe gaseous product and often less than 3 percent or 2 percent dependingon the particular processed organic-carbon-containing feedstock used.

To avoid passing through the liquid phase, the solid surface of theprocessed organic-carbon-containing feedstock should reach thesublimation temperature immediately. In some embodiments, this is within1 millisecond. In some embodiments, the time is within less than 0.1millisecond. In still others it is within less than 0.01 millisecond.

Some embodiments have a single reaction chamber. These are constructedto withstand the temperature changes associated with passing fromambient to operating sublimation temperatures during start up operationand the reverse during shutdown operations. Features may include thickerwalls and/or the use of supporting elements such as gussets where theconversion part of the reaction chamber wall is in communication withthe side of the hot box.

The first powered transport mechanism is located within the reactionchamber and is configured to convey sublimation products of theprocessed organic-carbon-containing feedstock through the reactionchamber as the processed organic-carbon-containing feedstock istransformed into product gas fuel and solid char fuel. Some embodimentshave a reaction chamber that comprises a tube containing the firstpowered transport mechanism. The reaction chamber also has a head spacein communication with the tube for the collection of product biogas fuelas it is created. The first powered transport mechanism is configured toadvance the solid portions of the processed organic-carbon-containingfeedstock, particularly the low-density forms of the processedorganic-carbon-containing feedstock. It is also configured to assistintermixing with the heat of the surface of the reaction chamber toassist in maintaining a stable operating sublimation temperature incontact with the solid parts of the feedstock as product biogas fuelcontinues to be removed from the solid parts of the feedstock. The firsttransport mechanism is one that is able to effectively operate at asublimation temperature and not be adversely impaired by thermalexpansion and contraction during the starting up and cooling down phasesof operation. One example of an effective first transport mechanism isin an augur.

The gas-tight element is on both the input line and output line andconfigured to prevent hot product fuel biogas from adversely escapingfrom the reaction chamber. Leaks that permit product biogas fuel to exitthe reaction chamber in an unregulated manner can cause a serious safetyconcern. Combustible product biogas fuel in the presence of hot surfacescan cause fires and explosions. Examples of gas-tight elements effectivefor this purpose at the temperatures discussed are a rotary valve, arotary vacuum valve, and actuated double-gate valve. Alternatively, amore expensive configuration may include a box surrounding the hot boxof the sublimation sub-system with purge nitrogen under a positivepressure in the box to keep any escaping gas from becoming hazardous.

The operating pressure in the reaction chamber may be protected fromadverse instability from the product biogas fuel leaving in itsdischarge line by passing the product gas fuel through a pressureisolation element. This helps maintain the stable sublimation conditionswithin the reaction chamber. Pressure isolation elements include, forexample, bubblers and cyclones to maintain pressure in the reactionchamber. Alternatively, the pressure in the reaction chamber may becontrolled through the product biogas fuel being discharged into gastight holding tanks.

Some embodiments of the system have at least two substantiallyhorizontal reaction chambers that are in communication with each otherin series, and the first powered transport mechanism has a part of ashaft that extends outside each reaction chamber and the hot box.Embodiments with more than one reaction chamber in series providesystems able to process higher amounts of carbon-containing feedstockwith similar footprints to that of some systems having a single reactionchamber. These embodiments further comprise an adjustable sealingelement located outside the hot box at the region of the hot boxsurrounding a collar about the extended part of the first poweredtransport mechanism. The adjustable sealing element is configured toprevent the adverse entry from outside the hot box of external oxygenentering the hot box during changing temperatures of startup andshutdown operations, and during steady-state sublimation operation.Leaks that permit oxygen to enter the hot box from the outside orproduct gas fuel to enter from the reaction chamber can causeundesirably large fluctuations in the operating sublimationtemperatures. They represent an additional and uncontrolled source ofheat when they combust.

Each sealing element comprises an adjustable plate and an adjustableseal to permit satisfactory exclusion of additional undesirable oxygenleaking into the hot box or reaction chamber through undesirable leakscreated during thermal expansion and contraction of elements of thesystem during startup and shutdown operations. The adjustable platecomprises a substantially vertical plate that is adjustably attached tothe hot box and configured to vertically move the collar about theextended part of the shaft of the first powered transport mechanism toprevent adverse contact between collar and the shaft. The adjustableseal is in communication with the adjusting plate, located about theextended portion of the shaft of the first powered transport mechanismand comprises a cone and rope configuration designed to maintain agas-tight seal about the shaft of the first powered transport mechanismas it extends from the hot box.

The residence time in the reaction chamber varies with the nature of theprocessed organic-carbon-containing feedstock and the quantity beingprocessed. Typically, between at least 50 percent by weight and over 90percent by weight of processed organic-carbon-containing feedstock canbe converted into product gas fuel with the remainder being solid charfuel having an energy density similar to coal. Longer residence timesallow more methane units to reassociate from the disassociated gas andmay result in a higher conversion to product gas fuel approaching over70 weight percent to over 90 weight percent. Residence times may rangefrom less than 10 minutes in some embodiments to less than 5 minutes insome embodiments to less than 2 minutes in some embodiments. Excessivelylong residence times have no adverse effect on the conversion once thetheoretical conversion is substantially achieved.

In some embodiments the reactor chambers further comprise manifoldsattached to the outside of the reaction chambers within the hot box. Thereaction chamber surface and the manifold are configured to allowdissociated gas to pass between the reaction chamber and the manifold toincrease the time the disassociated gas is exposed to sublimationtemperatures. In some cases, this additional time may result indissociating gases that have longer carbon—carbon structured chains suchas, for example, ethane, propane, and butane, to further disassociateinto methane.

Some embodiments of the system of the invention further comprise avertical support within the hot box and further beneath the lowersubstantially horizontal reaction chamber to support its weight duringstartup, shutdown, and operating conditions where thick reaction chamberwalls and support elements such as gussets are not desirable or notfeasible to provide adequate support. Generally, the vertical support isconfigured to be dimensionally stable to within about 2.5 cm (about oneinch) in the vertical direction over temperature variations betweenambient temperature and about 850° C. that may occur during the startup,operation, and shutdown of the substantially horizontal reactionchamber.

Vertical dimensional stability is achieved by the use of insulation incombination with the use of cooling material flowing through the supportin addition to the use of insulation. The cooling material is thatcommonly associated with cooling and includes, for example, water;refrigerants such as halogenated gas, carbon tetrachloride,chlorofluorocarbons, hydrochlorofluorocarbons, ammonia, carbon dioxide,ethane, propane, ether, and dimethylether; gaseous coolants such as air,hydrogen, inert gases, and sulfur hexafluoride; liquid coolants such aswater, ethylene glycol, diethylene glycol, propylene glycol, and Freon®by DuPont; and solid coolants such as dry ice.

Cooling materials may pass through or around a vertical support in anymanner that maintains the desired vertical dimensional stability. Whenthe vertical support is not cooled, thermal expansions may result invertical expansions of several inches. This is enough to cause welds inthe supported reaction chamber to break and leak product gas fuel intothe hot box or out into the environment. As discussed above, this cancause a safety issue and can adversely destabilize the operatingtemperature profile in the reaction chamber. Some embodiments may havethe cooling material pass horizontally along the vertical support wallsnear the hot reaction chamber that is being supported. Some embodimentsmay have cooling material flow vertically up into the shaft of thevertical support. Other configurations are also possible as long as theylimit vertical thermal expansion sufficiently to not cause leaks inwelds in the reaction chamber.

Some embodiments of the system may further comprise a preparationchamber that is outside the hot box. This is useful whencarbon-containing feedstock is not supplied in a dried and compressedmanner. The preparation chamber is in communication with thesubstantially horizontal reaction chamber, is configured to remove somefree water and oxygen from the processed organic-carbon-containingfeedstock, and is configured to compress the processedorganic-carbon-containing feedstock into a plug before it enters thesubstantially horizontal reaction chamber.

The preparation chamber also comprises a second powered transportmechanism that is located partly within the preparation chamber and hasa part that extends outside the preparation chamber. The preparationchamber is configured to perform one or more of moving the processedorganic-carbon-containing feedstock through the preparation chamber andcompressing the processed organic-carbon-containing feedstock within thepreparation chamber as it is dried of more free water.

Heat may be supplied internally for the drying function. In someembodiments, the heat used to dry the processedorganic-carbon-containing feedstock comes from the combustion gasses inthe hot box. In some embodiments, the heat may come from at least one ofthe hot product gas fuel and the solid char fuel through heat conveyancedevices such as, for example, heat exchangers.

In some embodiments, the preparation chamber may be subdivided into adrying chamber and a compression chamber where additional drying mayoccur. The compression chamber may be equipped with its own secondpowered transport mechanism. The drying chamber may be equipped with itsown third powered transport mechanism. In this embodiment, the dryingchamber or pre-preparation chamber is in communication with thecompression chamber or preparation chamber and is configured to reducethe particle size of low density processed organic-carbon-containingfeedstock to a size and remove the bulk of initial water and trapped airto permit the processed organic-carbon-containing feedstock to be moreeasily conveyed through the preparation chamber of the system, moreeasily compressed there without entraining oxygen or water, and moreeasily heated there to a sublimation temperature without permitting theformation of a liquid phase. In this embodiment, a third poweredtransport mechanism that precedes and is in communication with thepre-preparation chamber, has a part that extends outside thepre-preparation chamber. The mechanism is configured to perform one ormore of moving the processed organic-carbon-containing feedstock throughthe pre-preparation chamber and compressing the processedorganic-carbon-containing feedstock within the pre-preparation chamberin more manageable sized particles.

In both cases, the individual transport mechanisms are to advanceprocessed organic-carbon-containing feedstock forward into a conditionfor sublimation. One example of a transport mechanism is an augur butothers are suitable if they accomplish the desired function.

The system of the invention may further comprise various units toprepare the processed organic-carbon-containing feedstock into acondition to be used by the system of the invention. Various feedstockmust have their size reduced as discussed above to dimensions that canbe dried, compressed, and sublimated in a timely manner. By way ofillustration, tires must be reduced to tire crumbs and straws or stalksmust be reduced to shapes that are more readily conveyed through thepreparation chamber of the system, more easily compressed there withoutentraining oxygen or water, and more easily heated there to asublimation temperature without permitting the formation of a liquidphase. Units may include, for example, devices that grind, chop, slice,or cut.

FIGS. 9 to 17 illustrate various embodiments of the sublimation oxygendeficient thermal systems described above. The same numbers are used forsimilar functional elements even if the embodiments are different. FIG.9 is a diagram of a side view of an embodiment of a system with a singlesubstantially horizontal reaction chamber having one pass. A system(900) is depicted with a hot box (910) containing a vent (912) thatsurrounds a reaction chamber (920). The vent is needed when the hot boxis heated with burners that create combustion products. When heat isgenerated by other sources of heat, excess gas may not be generated thatneeds to be vented. Reaction chamber 920 has a surface (921), andcontains a first transport mechanism (922), an augur, with a shaft(924). At one end of reaction chamber 920 and extending outside hot box910 is a front end (930) that processed organic-carbon-containingfeedstock enters into thorough an input line (932) with a rotary vacuumvalve (934) to isolate any sublimed gases within the reaction chamber.At the other end of the reaction chamber and extending outside hot box910 is a back end (940) where product gas fuel exits from a dischargeline (942) with a pressure isolation element (944) positioned to isolateany sublimed processed biogas within the reaction chamber and solidprocessed biochar fuel exits from a discharge line (946) with a rotaryvacuum valve (948) positioned to isolate any sublimed processed biogaswithin the reaction chamber.

FIG. 10 is a diagram of a side view of an embodiment of a system with areaction chamber having two passes, a flexible shaft seal, and a hightemperature adjustable shaft cover plate. System 900 is depicted withhot box 910 containing vent 912 that surrounds a reaction chamber 920and is on a base (914). Reaction chamber 920 with surface 921 isconfigured like an open “U” on its side with two horizontal passagesconnected with a vertical passage on the right ends. Each horizontalpassage contains first transport mechanism 922, an augur, with a shaft924. Each shaft extends out of the horizontal passages of reactionchamber 920 and hot box 910. For each shaft end, a high temperatureadjustable shaft seal plate (926) encloses each shaft collar (927) andadjustably fastens to the hot box. For each shaft end, an adjustablehigh temperature seal (928) is fastened on shaft collar 927 at one endand encompasses both a portion of shaft collar 927 and a portion of theextended shaft end of shaft 924. At the end of the first reactionchamber 920 and extending outside hot box 910 is front end 930 intowhich processed organic-carbon-containing feedstock enters thoroughinput line 932 with rotary vacuum valve 934 positioned to isolate anysublimed process biogas within the reaction chamber. At the end of thesecond reaction chamber 920 and extending outside hot box 910 is backend 940 where processed biogas fuel exits from discharge line 942 withcooling element 944 positioned to isolate any sublimed process biogaswithin the reaction chamber and solid char fuel exits from dischargeline (946) with rotary vacuum valve (948) positioned to isolate anysublimed processed biogas within the reaction chamber.

The high temperature adjustable seal and plate that is shown in FIG. 10may have various forms as long as the function is accomplished. Oneembodiment is illustrated in FIGS. 11A to 11E and FIGS. 12A to 12Eadjustable shaft seal plate 926. FIG. 11A is a diagram of a side view ofan embodiment of the high temperature adjustable shaft seal casing withthe rope seals compressed in place. Seal 928 comprises a casing (1000)that contains a double rope seal base plate (1010) in its front endfacing the end of shaft 1024. Base 1010 is connected to two rope seals(1020) to form a double rope seal. This construction is furtherillustrated in FIG. 11B. The backend of casing 1000 that faces hot box910 contains a boltable collar (1040) that is configured to affix shaftcollar 927 next to single rope seal 1020 on a single rope seal baseplate (1050) that is further illustrated in FIG. 11C.

FIG. 11B is a diagram of a view of an element of the embodiment of FIG.11A showing a back view of the frame holding the double rope seal. Theview is one of looking through casing 1000 from the end of shaft 924.Bolt holes (1060A) are depicted.

FIG. 11C is a diagram of a view of an element of the embodiment of FIG.11A showing a back view of the frame holding a single rope seal. Theview is one of looking through casing 1000 from hot box 910. Bolt holes(1060B) are depicted.

FIG. 11D is diagram of a front view and side view of an element of theembodiment of but not shown in FIG. 11A showing a cover that compressesthe double rope seal of FIG. 11B. The front view is of the side thatfaces the rope seal. A cover (1070) comprises a raised inner compressionring (1072) that has a sloping cross-sectional edge attached to an outersupport ring (1074) with bolt holes 1060A. When bolted to the holes ofFIG. 11B, raised inner compression ring 1072 pushes the rope seal inwardagainst the shaft to eliminate adverse leaks of air containing oxygenfrom entering the hot box during startup and shutdown temperatureexpansion and contraction cycles.

FIG. 11E is a diagram of a front view and side view of an element of theembodiment of but not shown in FIG. 11A showing a cover that compressesthe single rope seal of FIG. 11C. The front view is of the side thatfaces the rope seal. A cover (1080) comprises a raised inner compressionring (1082) that has a square cross-sectional edge attached to an outersupport ring (1084) with bolt holes 1060B. When bolted to the holes ofFIG. 11C, raised inner compression ring 1082 pushes the rope sealdownward against seal collar 1040 to eliminate adverse leaks of aircontaining oxygen from entering the hot box during startup and shutdowntemperature expansion and contraction cycles.

FIG. 12A is a diagram of the front view and side view of an embodimentof the high temperature adjustable cover plate showing a top half. Theupper half (1110) of high temperature adjustable seal plate 926comprises two adjustable holes (1112), connecting holes (1114), and asemicircular opening (1116) designed to fit around half of shaft collar927. The cross-section (1118) is straight.

FIG. 12B is a diagram of the front view and side view of the embodimentof the high temperature adjustable cover plate of FIG. 12A showing abottom half. The lower half (1120) of high temperature adjustable sealplate 926 comprises two adjustable holes (1122), connecting holes(1124), a semicircular opening (1126) designed to fit around half ofshaft collar 927, and a step plate (1125) that contains connecting holes1124 to permit a smooth surface to contact the hot box when assembled.The cross-section (1128) is stepped.

FIG. 12C is a diagram of the front view of the embodiment of the hightemperature adjustable cover plate of FIG. 12A showing the top half ofFIG. 12A and the bottom half of FIG. 12B joined.

FIG. 12D is a diagram of the front view of the assembled hightemperature adjustable cover plate in the cold temperature position. Asseen, because hot box 910 has not yet experienced thermal expansion,shaft 924 exits hot box 910 through collar 927 at a lower position toavoid adversely having collar 927 contact shaft 924 during operation.

FIG. 12E is a diagram of the front view of the assembled hightemperature adjustable cover plate in the hot temperature position. Asseen, because hot box 910 has thermally expanded in an upward mannerduring start-up heating operations, collar 927 must be moved upward toavoid adversely contacting shaft 924 during operation. Adjustable holes1112 and 1122 permit such adjustment. Some embodiments use manualadjustment. Some embodiments use automated adjustment.

FIG. 13 is a diagram of a side view of an embodiment of a system with areaction chamber having two passes, a flexible shaft seal, a hightemperature adjustable shaft cover plate, and a vertical support stand.This embodiment is similar to the embodiment shown in FIG. 10 except ahigh temperature vertical support (1200) is used to support reactionchamber 920 within hot box 910. Vertical support 1200 comprises avertical shaft (1210) and a cradle (1220) to hold reaction chamber 920.The stability of the vertical shaft and cradle configuration isreinforced with gussets (1230) attaching shaft 1210 to cradle 1220 andshaft 1210 to system base 914.

The high temperature vertical support stand that is shown in FIG. 13 mayhave various forms as long as the function is accomplished. Oneembodiment is illustrated in FIGS. 14A and 14B. A variation of thatembodiment is illustrated in FIG. 14C. FIG. 14A is a front view of anembodiment of a vertical stand showing a curved cradle and a horizontalring for passing coolant. The cradle is designed to conform to thebottom of reaction chamber 920. In embodiments of the system where thebottom of reaction chamber 920 is other than curvature, a differentconforming shape of the cradle would be employed. Shaft 1210 issurrounded with insulation (not shown). However, heat passing fromreaction chamber 920 through cradle 1220 to stand 1210 can causeadversely large vertical thermal expansion of shaft 1210 as discussedabove. A cooling ring (1240) horizontally displaced within the upperpart of shaft 1210 can be used to minimize thermal expansion of shaft1210 to satisfactory lengths over the ranges of temperatures employed bythe apparatus as discussed above.

FIG. 14B is a top view of the embodiment of FIG. 14A showing coolingring 1240.

FIG. 14C is a front view of an embodiment of a vertical stand showing acurved cradle and a vertical up and down cooling passage within thevertical shaft of the vertical stand.

FIG. 15 is a diagram of a side view of an embodiment of a system with areaction chamber having two passes and a four-pass bypass manifoldattached to the outside of the reaction chamber to increase residencetime. The system (1300) comprises a bypass manifold (1310 that is incommunication with the processed biogas within reaction chamber throughapertures (not shown) in the surface (921) of the reaction chamber andmanifold where they connect. This permits the deconstructed gas productto experience extended residence times where appropriate for desiredconversion of processed organic-carbon-containing feedstock into productgas fuel and solid char fuel.

FIG. 16 is a diagram of a side view of an embodiment of a system with areaction chamber having two passes, a compression chamber, and a dryingchamber. This system is similar to that shown in FIG. 14 with additionalprocessing chambers. The passage of material as it enters and progressesthrough the system until it exits as product fuel is shown by a heavyline. System 1500 comprises a preparation chamber (1510) for compressingcarbon-containing feedstock into a plug prior to entry into the frontend 930 of the reaction chamber. A second powered transport mechanism(1520) is inside the chamber to accomplish the compression. Someadditional drying may also occur here. A pre-preparation chamber (1530)is in communication with the preparation chamber 1510 with a thirdpowered transport mechanism (1540) to convey the processedorganic-carbon-containing feedstock in a heated environment to dry thefeedstock. A channel (1550) is used to funnel hot combustion gases fromthe hot box into the pre-preparation chamber to assist in part or all ofthis drying.

Another embodiment of the invention involves a process for converting acarbon-containing compound to product gas fuel and solid char fuel. Theprocess comprises at least four steps. The first step is inputtingprocessed organic-carbon-containing feedstock into a substantiallyhorizontal sublimating reaction chamber largely contained within a hotbox and configured to be able to heat from an ambient temperature to anoperating sublimation temperature, operate at a sublimation temperature,and cool from an operating sublimation temperature to an ambienttemperature without leaking any hot product gas fuel from the reactionchamber into the hot box or atmosphere, or leaking any oxygen fromoutside the hot box into the hot box. The second step is heatingprocessed organic-carbon-containing feedstock to a sublimatingtemperature before it is able to form a liquid phase. The third step ismaintaining the temperature at a sublimation temperature for a residencetime that is as long a time as needed to convert the carbon-containingfeedstock to product gas fuel and solid char fuel. The fourth step isseparating the product gas fuel from the solid char fuel.

Heat generated by the process may be used in various ways. Someembodiments may use direct heated combustion gases from the hot box to apre-preparation chamber to dry the processed organic-carbon-containingfeedstock before it enters a preparation chamber for compression, ifneeded, and a sublimation chamber. Some embodiments may use the heat forother purposes such as heating buildings.

Heat used to sublimate the feedstock may be supplied by combusting partof the product fuel gas. Sublimation temperatures can be maintained witha small fraction of the product gas fuel being used as fuel for burnersas discussed above.

Vertical Sublimation Oxygen-Deficient Thermal Sub-System

The vertical sublimation oxygen-deficient thermal sub-system comprisesthree elements, a vertical reaction chamber, a first powered transportmechanism, and a self-adjusting seal. The first, at least onesubstantially vertical reaction chamber, is configured to heat theprocessed organic-carbon-containing feedstock without external catalystor additional water, carbon dioxide, or carbon monoxide, to an operatingsublimation temperature in a time frame that is short enough to sublimeat least part of the processed organic-carbon-containing feedstockwithout creating substantially any liquid. The second, the first poweredtransport mechanism, is located partly within the reaction chamber, hasan extended part that extends outside the reaction chamber, and isconfigured to convey sublimation products of the processedorganic-carbon-containing feedstock through the reaction chamber as theprocessed organic-carbon-containing feedstock is transformed into biogasand processed biochar. The third, the self-adjusting seal, is configuredto continuously contain the processed biogas within the reaction chamberat the region surrounding the extended part of the powered transportmechanism during changing temperatures of startup and shutdownoperations, and during steady-state sublimation temperature duringoperation.

To better understand this sub-system, the vertical sublimationsub-system will be discussed with reference at times to a particularembodiment or embodiments. However, it is understood that otherembodiments may be used as long as they perform the sublimation desired.

The vertical sublimation oxygen-deficient thermal sub-system is designedfor processing high-density feedstock, like tires, plastic, wood, andcoal. High density means that the feedstock has a high weight per unitvolume. Feedstock preparation will be dictated by characteristics of theprocessed organic-carbon-containing feedstock such as size or thickness,and density of the processed organic-carbon-containing feedstock fromthe beneficiation sub-system. In general the desirable size or thicknessis on the order of less than 0.5 inch (13 mm) in the longest dimensionof the particle. The particle size is important in the verticalsub-system because denser materials take more time to heat thoroughlyfrom the particle surface to its internal midpoint. Volatile gases areformed at the midpoint or center of the particle and have to travel tothe surface of the particle where they are released into the reactionchamber environment. The sublimed gas should be created as quickly aspossible and stay in the gas phase at all times for best conversion ofthe processed organic-carbon-containing feedstock into processed biogasand processed biochar. A high density feedstock allows the particles tofall through the reaction chamber and reach the bottom where they areeventually separated in to the gas and solid forms. At times, theprocessed organic-carbon-containing feedstock may have to be furthercompressed to achieve desired density and further manipulated to achievedesired particles sizes.

After the processed organic-carbon-containing feedstock is properlyprepared, it is conveyer to the top of the vertical sub-system by suchas, for example, an auger or some other material conveying device.During the transportation of the feedstock, heat may be recycled fromdownstream processes to maximize removal of any free water. Then thefeedstock is deposited into a hopper of a compression auger. Thecompression auger reduces the free water and entrained air content. Thiswill increase the heat absorption by the feedstock and reduce the amountof oxygen present. Reducing the oxygen content that comes from the waterand air will result in less carbon dioxide and carbon monoxide in theproduced biogas and less contaminants in the processed biochar. Afeedstock plug or seal is created at the end of the compression screw atthe entrance point to the reaction chamber. Thus, when the feedstockenters the reaction chamber, the produces biogas that is created doesnot travel back and escape to create a hazardous situation.

As the feedstock enters the reaction chamber, the feedstock isimmediately subjected to a stream of superheated gas that sublimes thevolatiles from the feedstock. As the volatilized gas and the devolatizedfeedstock, now reduced to carbon, falls the length of the reactionchamber tube, the volatilized gas and the carbon solid intermingle,react, and gain momentum. At the bottom of the shared common reactionchamber tube, the devolatilized carbon drops down into a collectionhopper and the gas stream is split into two streams that move laterallyover and up two reaction chamber tubes on either side of the common downtube. The reaction chamber looks like two of the letters “O” that areconnected in the middle. The two up tubes of the reaction chamber nowcarry the hot gas upward and assisted by a turbine fan. Two-thirds ofthe way up each of the two up-tubes is a super-heater that raises thetemperature of the gas. It is more economical to super heat just the gasthan to heat the incoming feedstock. The super heated gas is nowreaching the top of the up reaction chamber tubes and is directed fromthe top of each up tube, laterally, over to the top of the shared commondown tube where the entrance of the feedstock is located. The superheated gas then is used to sublime the incoming feedstock and everythingrepeats itself in the down tube in a closed loop cycle. When the tubesin the reaction chamber are in equilibrium and balanced, the producedbiogas is pulled through an outlet at the top of one of the upwardreaction tubes, cooled, and stored as processed biogas. The carbon exitsthe bottom of the common middle tube and is transported by auger,cooled, and collected for storage as processed biochar.

The reaction chamber in the sub-system is a three dimensional,rectangular box with the longest side perpendicular to the ground. Onthe topside is a compression screw and feedstock entrance port. On thebottom side is a collection cone with an exit auger at the bottom of thecone for produced biochar.

Inside the reaction chamber heater box are three connected andcontinuous tubes with the middle tube shared between the two outsidetubes such that the three tubes act as one tube. The middle tube acts asa down draft while the two outside tubes act as updrafts. In thisconfiguration, the feedstock enters at the top of the middle tube andfree falls as the feedstock traverses the length of the tube. This iswhere the sublimation of the feedstock occurs. There is a junction atthe bottom of the middle tube where the tube makes two lateral splits.At the end of each lateral split, a tube continues up on both sides ofthe middle tube. Thus, all three reaction chamber tubes are continuousand sealed so that the reaction chamber remains isolated from outsidecontaminants and only contains the feedstock that is to be processed. Noexternal air, steam, or catalyst is introduced.

On the outside of the reaction chamber, but connected to it, are twoburners that heat the space between the inside of the outside box walland the outside of the inside wall of the internal tube configuration.This space is heavily insulated and keeps the reaction chamberenvironment at a minimum temperature.

In operation, the sublimated feedstock at the bottom of the middledowndraft tube of the reaction chamber has separated into adevolatilized carbon and processed biogas. The stream of processedbiogas splits and travels laterally to the outside updraft reactionchamber tubes. The devolatilized carbon settles into the collection coneand is removed by an auger. The devolatilized carbon is still in theheated reaction chamber environment so this acts as a polishing step tomake sure all of the volatile gases that can be created will be capturedand continue in the subliming process through the reaction chamberupdraft tubes. After some residence time, the carbon can be passedthrough an auger into a cooling chamber and then stored as processedbiochar. Residence time depends on the nature and volume of theprocessed organic-carbon-containing feedstock. In some embodiments, theresidence time is less than 10 minutes, in some less than 7 minutes, insome less than 5 minutes, in some less than 3 minutes, and in some lessthan 2 minutes.

At the split at the bottom of the middle downdraft tube the carbon dropsout and only the processed biogas continues to travel laterally to theoutside updraft tubes of the reaction chamber. The product processedbiogas travels up the updraft tubes carried by their own inertia fromtraversing the downdraft tube with some optional assistance by a turbinefan placed at the top of the updraft tubes. Attached on the outside wallof both updraft tubes but still inside of the external wall of thereaction chamber box is laced one super heater on each outside tube.During startup, as the processed biogas traverses the updraft tube backto the top of the top part of the reaction chamber tubes, it passesthrough the super heaters and the temperature in the reaction chamber isincreased to a preselected temperature that is the desired equilibriumtemperature. It is more economical to super heat just the processedbiogas than the input processed organic-carbon-containing feedstock. Thesuperheating assists in the further dissociation of the processed biogaswhen it comes in contact with the devolatilized carbon in the downdrafttube.

As the two superheated processed biogas streams reach the top of the twooutside tubes, they are comingled with the fresh incoming feedstock asit enters the middle downdraft tube and sublime that feedstock. Thecycle of the fresh feedstock coming into the reaction chamber, the freshfeedstock mixing with the superheated processed biogas and the mixtureentering the reaction chamber tubes completes the reaction processingcycle. When the reaction reaches equilibrium and balance, more feedstockis added and both processed biochar and processed biogas is removedaccording to predetermined production rates.

FIG. 17 is a diagram of a side view of an embodiment of a system with asubstantially vertical reaction chamber. This system (1600) has acompression feed system (1610) that is in communication with acompression auger (1620). Processed organic-carbon-containing feedstockfollows a double circular path (1630) with circulating processed biogas(1640) a reaction chamber (1632) that is more clearly illustrated inFIG. 17A. Reaction chamber 1632 is in a hot box (1665). A bypass (1645)directs some overflow heat from hot box 1665 to preheat the incomingprocessed organic-carbon-containing feedstock in compression feed system1610. Heat exchangers 1650 within hot box 1665 super heat circulatingprocessed biogas 1640 to achieve and maintain the target sublimingtemperature. A carbon auger (1660) removes the processed biochar. Therest of the overflow heated gas leaves hot box 1665 through a heaterexhaust exit (1670) and processed biogas passes through a processedbiogas exhaust exit (1680).

FIG. 17A is a diagram of tube array of the embodiment shown in FIG. 17.A reaction chamber (1632) is depicted with a tube array comprising amiddle downdraft reaction tube (1634) bracketed by two outer updraftreaction tubes (1636) within hotbox 1665. Heat exchangers 1650 heatouter updraft reaction tubes 1636 below the cross tee and the inputdowndraft tube 1634 above the cross tee. Excess hot gas leaves throughexhaust exit 1670 and processed biogas leaves through outlet 1680 inreaction chamber 1632.

Microwave Sub-System

The microwave sub-system is another form of the heating sub-system thatis used to convert the processed organic-carbon-containing feedstockfrom the beneficiation sub-system into a processed biochar that issubsequently made into a processed biomass/coal blended compactaggregate of the invention. The sub-system comprises a processed biocharcomposition made from a processed organic-carbon-containing feedstockthat passes through a microwave process sub-system. The sub-systemincludes at least one reaction chamber within a microwave reflectiveenclosure and comprising at least one microwave-transparent chamber walland a reaction cavity configured to hold the processedorganic-carbon-containing feedstock in an externally suppliedoxygen-free atmosphere. A microwave sub-system includes at least onedevice configured to emit microwaves when energized. The microwavedevice is positioned relative to the reaction chamber so that themicrowaves are directed through the microwave-transparent chamber walland into the reaction cavity. The sub-system also includes a mechanismthat provides relative motion between the microwave device and thereaction chamber. The processed biochar composition includessubstantially no free water. Also the processed biochar compositionincludes a number of pores per volume that is at least 10 percent morethan would have been in a char made with the same feedstock but using athermal process that creates a liquid phase during the process. Thecharacteristics of the feedstock and resulting processed biochar havealready been discussed above. The microwave process used to make theprocessed biochar of the invention is now discussed.

In the following description of the illustrated embodiments, referencesare made to the accompanying drawings that help to illustrate variousembodiments of the microwave process used to make the processed biocharof the invention. It is to be understood that other embodiments of theprocess may be utilized and structural and functional changes may bemade without departing from the scope of the present invention.

The following description relates to approaches for processing solidand/or liquid organic-carbon-containing feedstock into fuels, e.g.,diesel fuels, gasoline, kerosene, etc., by microwave enhanced reactiondeconstruction processes.

Deconstruction, also referred to as “cracking”, is a refining processthat uses heat to break down (or “crack”) hydrocarbon molecules intoshorter hydrocarbon chains which are useful as fuels. Deconstruction maybe enhanced by adding a catalyst to the feedstock which increases thespeed of the reaction and/or reduces the temperature and/or theradiation exposure required for the processes. Furthermore, thecatalyst, such as zeolite, has a nanostructure which allows onlymolecules of a certain size to enter the crystalline grid or activatethe surface areas of the catalyst and to interact with the catalyst.Thus, the catalyst advantageously is very effective at controlling theproduct produced by the reaction processes because only substanceshaving a specified chain length may be produced using the catalyticprocess. Catalytic deconstruction is particularly useful fortransforming biomass and other organic-carbon-containing feedstock intofuels useable as transportation or heating fuels.

One aspect of efficient deconstruction is the ability to heat andirradiate the feedstock substantially uniformly to the temperature thatis sufficient to cause deconstruction as well as activate the catalyst.Upon deconstruction, long hydrocarbon chains “crack” into shorterchains. Microwave heating has been shown to be particularly useful inheating systems for thermal deconstruction. Heating systems such asflame, steam, and/or electrical resistive heating, heat the feedstock bythermal conduction through the reaction chamber wall. These heatingsystems operate to heat the feedstock from the outside of the reactionchamber walls to the inside of the feedstock, whereas microwaves heatuniformly throughout the width of the reaction chamber. Usingnon-microwave heating sources, the heat is transferred from the heatsource outside wall to the inside of the vessel wall that is in directcontact with the feedstock mixture. The heat is then transferred to thesurfaces of the feedstock and then transferred, again, through thefeedstock until the internal areas of the feedstock are at a temperaturenear the temperature of the reaction chamber wall.

One problem with this type of external heating is that there are timelags between vessel wall temperature transmission and raising thefeedstock temperature that is contained in the center of the vessel aswell as the internal area of the feedstock matrix. Mixing the feedstockhelps to mitigate these conditions. Still, millions of microenvironmentsexist within the reactor vessel environment and the feedstock particlesthemselves. This causes uneven heat distribution within the reactionchamber of varying degrees. These variant temperature gradients causeuncontrollable side reactions to occur as well as degradation of earlyconversion products that become over-reacted because of the delay inconversion reaction timeliness. It is desirable to produce and retainconsistent heating throughout the feedstock and the reaction products sothat good conversion economics are achieved and controllable. Microwaveheating is an efficient heating method and it also serves to activatecatalytic sites.

Embodiments of the invention are directed to a reaction chamber systemthat can be used to process any organic-carbon-containing feedstock,whether solid and/or liquid, to extract the volatile organic compoundsin the feedstock at a temperature range that will produce liquidtransportation fuels.

Microwaves are absorbed by the water molecules in the material that isirradiated in the microwave. When the water molecules absorb themicrowaves, the molecules increase their vibrorotational motions, whichcreate heat by friction, and the heat is convected to the surroundingmaterial. The reason microwaves are absorbed by water molecules isspecific to the covalent bonds that attach the hydrogen to the oxygen ina water molecule. The oxygen atom in water has a large electronegativityassociated with it. Electronegativity for an element is its propensityto collect extra electrons, either completely in an ionic bond orthrough skewing the electron cloud of a covalent bond toward thatelement. The driving force is from quantum chemistry, namely the fillingof the 2p shell of oxygen from the addition of 2 electrons. Theelectronegativity scale, driven by the stability of filling the outerelectron shell, starting at the most electronegative element, isF>O>N>Cl>Br>S>C>H. Therefore, the valence electrons in water are skewedtoward the oxygen, creating a permanent electric dipole moment with thenegative pole toward the oxygen and the positive pole between the twohydrogen atoms. The electrons from the two hydrogen atoms are drawncloser to the oxygen atom. This gives this end of the molecule a slightnegative charge and the two hydrogen atoms then have a slight positivecharge. The consequence of this distortion is that the water moleculepossesses a permanent electric dipole. The dipole feature of the watermolecule allows the molecule to absorb the microwave radiation andincreases the rotational speed of gaseous water molecules and/orincreases the low frequency vibrational movements associated withfrustrated rotations of the extended structure of liquid water. Theincreased motion of the water molecules causes friction that turns toheat and then convects out into the irradiated material.

To take advantage of this feature of microwave radiation, a reactionchamber system described herein takes advantage of microwave irradiationand heating in processing feedstock that contains carbon and can beconverted to transportation fuels. The reactor may be made from asubstantially microwave transparent substance such as quartz, acrystalline material that is substantially transparent to microwaveradiation. Because quartz can be manipulated into many shapes, itprovides design discretion for shaping the reaction chamber, but in oneexample the reaction chamber is configured in the shape of a tube orcylinder. The cylindrical shape allows for the feedstock to feed in oneend and exit at the opposite end. An example of a suitable reactionchamber would be a quartz tube that is about four feet (1.2 meters) longwith a wall thickness of about 3/16 inch (4.8 mm).

The microwave reaction chamber is surrounded by a microwave reflectiveenclosure. This causes the microwave radiation to pass repeatedlythrough the reaction chamber and devolatize theorganic-carbon-containing feedstock after the water, if present, isevaporated and driven off. The microwave reflective enclosure is anythat reflects microwaves. Materials include, for example, sheet metalassembled as Faraday cages that are known to the art.

Microwave radiation is generated by a magnetron or other suitabledevice. One or more microwave producing devices, e.g., magnetrons can bemounted external to the quartz tube wall. Magnetrons come in differentpower ranges and can be controlled by computers to irradiate theprocessing feedstock with the proper power to convert the feedstock tomost desirable fuel products efficiently, given the residence time inthe reactor. In one application, the magnetron can be mounted on a cagethat would rotate around the outside of the reactor tube as well astravel the length of the reactor tube. Feedstock traveling through thelength of the inside of the tube will be traveling in a plug flowconfiguration and can be irradiated by fixed and/or rotating magnetrons.A computer may be used to control the power and/or other parameters ofthe microwave radiation so that different feedstock, with differentsizes and densities can be irradiated at different parameter settingsspecific to the feedstock and thus convert the feedstock moreefficiently.

These configurations of a reactor will allow efficient processing offeedstock, from relatively pure feedstock streams to mixed feedstockstreams that include feedstock of different densities, moisturecontents, and chemical makeup. Efficiencies can occur because the fuelproducts are extracted from the reactor chamber as they are vaporizedfrom the feedstock, but further processing of the remaining feedstockoccurs until different fuel products are vaporized and extracted. Forexample, dense feedstock, such as plastics, take longer to process intoa useable fuel than less dense feedstock, such as foam or wood chips.The microwave sub-system described herein continues to process densefeedstock without over-processing the earlier converted products fromthe less dense feedstock. This is accomplished by using both stationaryand rotating microwave generators.

One example of a mixed feedstock would be unsorted municipal solidwaste. In some implementations, catalyst may be added in the feedstockwhich helps in the conversion of the feedstock as well as the speed atwhich the conversion can progress. A catalyst can be designed to reactat the preset processing temperature inside the reactor or to react withthe impinging microwave radiation. In some embodiments, no catalyst isrequired. In other embodiments, the catalyst may be a rationallydesigned catalyst for a specific feedstock.

The plug flow configuration with the reactors described herein willallow adjustments to the residence time that the feedstock resideswithin the reactor core for more efficient exposure to the heat and theradiation of the microwaves to produce the desired end products.

Inlets and/or outlets, e.g., quartz inlets and/or outlets can be placedalong the walls of the reaction chamber to allow for pressure and/orvacuum control. The inlets and outlets may allow the introduction ofinert gases, reactive gases and/or the extraction of product gases.

Thus, the design of the microwave-transparent reaction chamber, the useof microwaves as a heating and radiation source with fixed and/orrotating magnetrons, plug flow processing control, with or without theuse of catalysts, will allow the processing of anyorganic-carbon-containing feedstock. An advantage to beneficiating theorganic-carbon-containing feedstock is that it has, to a large extent,already been brought to an acceptable moisture level and is alreadyfairly homogeneous. For homogeneity on the macro-scale, the output fromdifferent organic-carbon-containing feedstock inputs have substantiallysimilar characteristics (e.g. energy density, consistency, moisturecontent), and these characteristics extend throughout the material. On,the molecular scale, with fewer salts present, there are fewermicroenvironments where the microwaves would deposit energy differentlythan in the bulk of the organic-carbon-containing feedstock. Therefore,the heating would be more uniform from beneficiatedorganic-carbon-containing feedstock than from raw unprocessedorganic-carbon-containing feedstock inputs.

A microwave sub-system in accordance with embodiments of the inventionincludes a reaction chamber having one or more substantiallymicrowave-transparent walls and a microwave heating/radiation system.The microwave heating/radiation system is arranged so that microwavesgenerated by the heating/radiation system are directed through thesubstantially microwave-transparent walls of the reaction chamber andinto the reaction cavity where the feedstock material is reacted withoutsubstantially heating the walls of the reaction chamber. To enhance thetemperature uniformity of the feedstock, the reaction chamber and theheating/radiation system may be in relative motion, e.g., relativerotational and/or translational motion. In some implementations, theheating system may rotate around a stationary reaction chamber. In someimplementations, the feedstock within the reaction chamber may rotate bythe use of flights with the heating/radiation system remainingstationary. In some implementations, the reaction chamber may rotatewith the heating system remaining stationary. In yet otherimplementations, both the reaction chamber and the heating/radiationsystem may rotate, e.g., in countercurrent, opposing directions. Tofurther increase temperature uniformity, the system may include amechanism for stirring and/or mixing the feedstock material within thereaction chamber. The reaction chamber may be tilted during reactionprocess, for example, to force the feedstock to go through the catalyticbed.

FIGS. 18A and 18B illustrate side and cross sectional views,respectively, of a microwave sub-system (1800) for convertingorganic-carbon-containing feedstock to liquid fuel and processed biocharfuel in accordance with embodiments of the invention. Although areaction chamber (1810) may be any suitable shape, reaction chamber 1810is illustrated in FIGS. 18A and 18B as a cylinder having a cylindricalwall (1811) that is substantially transparent to microwaves in thefrequency range and energy used for the reaction process. Reactionchamber 1810 includes a reaction cavity (1812) enclosed by cylindricalwall 1811. Microwave sub-system 1800 includes a transport mechanism(1818) configured to move the feedstock through the reaction chamber.The operation of microwave sub-system 900 with regard to the reactionstaking place within reaction chamber 1810 may be modeled similarly tothat of a plug flow reactor.

As illustrated in FIG. 18A, a microwave sub-system includes transportmechanism 1818 for moving the feedstock material through reactionchamber 1810. Transport mechanism 1818 is illustrated as a screw auger,although other suitable mechanisms, e.g., conveyer, may also be used.Transport mechanism 1818 may further provide for mixing the feedstockwithin the reaction chamber. In some embodiments, reaction chamber wall1811 may have a thickness of about 3/16 inch (4.8 millimeters). Thesmoothness of reaction chamber wall 1811 facilitates the movement of thefeedstock through reaction chamber 1810.

A heating/radiation subsystem (1815) may include any type of heatingand/or radiation sources, but preferably includes a microwave generator(1816) such as a magnetron which is configured to emit microwaves (1813)having a frequency and energy sufficient to heat theorganic-carbon-containing feedstock to a temperature sufficient tofacilitate the desired reaction of the feedstock, for example, fordeconstruction of the feedstock, microwaves in a frequency range ofabout 0.3 GHz to about 300 GHz may be used. For example, the operatingpower of the magnetrons may be in the range of about 1 Watt to 500kilowatts. Magnetron 1816 is positioned in relation to reaction chamber1810 so that microwaves 1813 are directed through wall 1811 of reactionchamber 1810 and into reaction cavity 1812 to heat and irradiate thematerial therein. A mechanism (1817) provides relative motion betweenmagnetron 1816 and reaction chamber 1810 along and/or aroundlongitudinal axis 1820 of reaction chamber 1810. In some embodiments,mechanism 1817 may facilitate tilting reaction chamber 1810 and/ormagnetron 1816 at an angle θ (see FIG. 18C) to facilitate the reactionof the feedstock and/or the extraction of gases, for example. In theembodiment illustrated in FIGS. 18A-C, magnetron 916 is positioned onrotational mechanism 1817, such as a rotatable cage or drum that rotatesmagnetron 1816 around stationary reaction chamber 1810. In someimplementations, the rotation around the chamber may not be complete,but the rotation path may define an arc around the circumference of thereaction chamber. The rotation may occur back and forth along the pathof the arc. As previously mentioned, in some embodiments, reactionchamber 1810 may be the rotating component, or both magnetron 1816 (alsocalled the heating/radiation subsystem) and reaction chamber 1810 mayrotate, e.g., in opposing, countercurrent directions. The rotationbetween the reaction chamber and the magnetron provides more evenheating and more even microwave exposure of the feedstock withinreaction cavity 1812, thus enhancing the efficient reaction chemistry ofthe feedstock and/or other processes that are temperature/radiationdependent, such as removal of water from the feedstock. The rotationlessens the temperature gradient and/or maintains a more constantmicrowave flux across the plug inside the reaction chamber.

Reaction chamber 1810 may include one or more entry ports (1820), e.g.,quartz entry ports, configured to allow the injection or extraction ofsubstances into or out of reaction cavity 1812. Reaction chamber 1810 isalso surrounded by a microwave-reflective enclosure (1822). In oneimplementation, the quartz ports may be used to extract air and/oroxygen from the reaction cavity. Extraction of air and/or oxygen may beused to suppress combustion which is desirable for some processes.

For example, in certain embodiments, microwave sub-system 1800 may beused to preprocess the feedstock through compression and/or removal ofair and/or water. In this application, gases such as hydrogen and/ornitrogen may be injected through one or more ports 1820 to hydrogenateand/or suppress combustion of the feedstock. Reaction chamber 1810 mayalso include one or more exit ports (1821), e.g., quartz exit ports,configured to allow passage of water, water vapor, air, oxygen and/orother substances and/or by-products from reaction chamber 1810. In otherembodiments, the processed organic-carbon-containing feedstock isalready sufficiently compressed and reduced in both air and water to beintroduced directly into the reaction chamber.

FIG. 18D is a diagram illustrating a microwave-sub-system (1850) forproducing fuel from organic-carbon-containing feedstock in accordancewith embodiments of the invention. Microwave sub-system 1850 includes aninput hopper (also referred to as a load hopper) 18951) configured toallow introduction of the feedstock material into microwave sub-system1850. A gearmotor auger drive (1852) provides a drive system for theauger (1853) that transports the feedstock through microwave sub-system1850. As the feedstock is compressed in load hopper 951, air isextracted through an atmosphere outlet (1854). A seal (1855) isolatesload hopper 1851 from a reaction chamber (1856) to maintain a level ofvacuum. Reaction chamber 1856 includes walls of a microwave-transparentmaterial. One or more stationary microwave heads 1857 are positioned atthe walls of the reaction chamber 1856. In addition, microwavesub-system 1850 includes one or more rotating microwave heads (1858). Inone implementation, each rotating microwave head is located at a fixedposition with respect the longitudinal axis (1860) of reaction chamber1856. The rotating microwave head is mounted on a slipring bearing(1859) which allows microwave head 958 to rotate around reaction chamber1856. A microwave reflective enclosure (1862) encompasses reactionchamber 1856. In some implementations rotating microwave head(s) 958 mayrotate around the longitudinal axis 1860 of the reaction chamber 1856 aswell as moving back and forth along the longitudinal axis 1860.Microwave sub-system 950 includes a seal at the exit of reaction chamber1856 to maintain the reaction chamber vacuum. In some embodiments, theorganic-carbon-containing feedstock is compressed in thesub-beneficiation system discussed earlier before it enters themicrowave sub-system and little if any air extraction is needed.

FIG. 19A is a block diagram of a microwave sub-system 1900 that uses oneor more of the reaction chamber illustrated in FIGS. 18A and 18B. Thereaction chamber 1920, 1930 may be arranged and/or operated in series orin a parallel configuration. An extraction process (1920) and a reactionprocess (1930) depicted in FIGS. 19A and 10B are illustrated asoccurring in two separate reaction chambers, e.g., that operate atdifferent temperatures. Alternatively, the extraction process and thereaction process may be implemented in a single reaction chamber withtwo separate zones, e.g., two separate temperature zones.

In microwave sub-system 1900 of FIG. 19, one or both of water/airextraction section 1920 and reaction section 1930 may be similar to thereaction chamber in microwave sub-system 1800 of FIGS. 18A and 18B.Organic-carbon-containing feedstock, such as, for example, one or moreof manure containing plant cells, wood chips, and plant-based cellulose,enters the microwave sub-system through a hopper (1911), and traversesan airlock (1912) to enter a feedstock preparation module (1913). Ifneeded, a catalyst, such as zeolite, and/or other additives that enhancethe reaction process, for example to adjust the pH, may be introducedinto microwave sub-system 1000 through input hopper 1911 and/or theentry ports (shown in FIG. 18B). In the feedstock preparation module1913, the feedstock material may be shredded to a predetermined particlesize that may be dependent on the properties of the feedstock, such asthe purity, density, and/or chemical composition of the feedstock. Ifused, the catalyst may be added at the time that the feedstock is beingprepared so that the catalyst is evenly dispersed within the feedstockmaterial before entering a reaction chamber (1931). In general, the lessuniform the feedstock, the smaller the particle size needed to provideefficient reaction.

After the initial feedstock preparation stage, the shredded and mixedfeedstock is transported by a transport mechanism 1915 into theextraction chamber 1921 of the next stage of the process. An air/waterextraction subsystem (1920), which performs the optional processes ofwater and/or air extraction prior to the reaction process, includes aheating/radiation module (1922) comprising at least a magnetron (1923)configured to generate microwaves (1926) that may be mounted on arotational or stationary mechanism (1927). If mounted on a rotationalmechanism, the mechanism rotates magnetron 1923 either partially orfully around extraction chamber 1921 as microwaves 1926 are directedthrough a wall (1924) of extraction chamber 1921 and into an extractioncavity (1925) impinging on and heating the feedstock therein. In someembodiments, heating module 1922 may utilize only one magnetron 1923 oronly two or more magnetrons without using other heat/radiation sources.

In some embodiments, heating/radiation module 1922 may utilize magnetron1923 in addition to other heat sources, such as heat sources that relyon thermal conduction through the wall of the extraction chamber, e.g.,flame, steam, electrical resistive heating, recycled heat from theprocess, and/or other heat sources. During the air and/or waterextraction process, the feedstock may be heated to at least 100 C, theboiling point of water, to remove excess water from the feedstock. Theexcess water (e.g., in the form of steam) and/or other substances mayexit extraction chamber 1921 via one or more exit ports. Additives tothe feedstock, such as inert and/or reactive gases including hydrogenand/or nitrogen, may be introduced via one or more input ports intoextraction chamber 1921 of the water/air extraction process. In additionto being heated and irradiated by microwaves, the feedstock may also besubjected to a pressurized atmosphere and/or a vacuum atmosphere and/ormay be mechanically compressed to remove air from extraction chamber1921.

After the optional air and/or water extraction process, transportmechanism 1915 moves the feedstock to the next processing stage, areaction section (1930) which involves the reaction process, e.g.,thermal deconstruction, of the feedstock. After the feedstock/catalystmixture enters a reaction chamber (1931) surrounded by the microwavereflecting enclosure (1938), the mixture is heated to a temperature thatis sufficient to facilitate the desired reaction. For example atemperature of in a range of about 200 C to about 350 C is used to crackthe hydrocarbons in the feedstock into shorter chains to produce liquidfuel through deconstruction. In addition to being heated, the feedstockmay also be subjected to a pressurized atmosphere or a vacuumatmosphere, and/or may be mechanically compressed in reaction chamber1931.

In some embodiments, heating/radiation in the reaction chamber 1031 isaccomplished using a magnetron (1933) emitting microwaves (1936).Magnetron 1033 may rotate relative to reaction chamber 1031. Aspreviously described in connection with the water extraction section1920, a rotating magnetron (1933) may be supported by rotationalmechanism (1937), such as a cage or drum. Rotational mechanism 1937allows relative rotational motion between magnetron 1933 and reactionchamber 1931. For example, magnetron 1933 may rotate completely aroundreaction chamber 1931 or the rotation of magnetron 1933 may proceed backand forth along an arc that follows the circumference of reactionchamber 1931. The rotating magnetron heating system 1933 may besupplemented using a stationary magnetron, and/or other conventionalheat sources such as a flame or electrical resistive heating. Rotatingmagnetron 1933 provides more even heating/radiation of the feedstockmaterial and catalyst within a reaction cavity (1935) and enhances theheating properties over that of stationary heat sources.

The cracked hydrocarbons vaporize and are collected in a condenser(1041) and liquefy and then are sent to a distiller (1940) to producethe diesel fuel, while heavier, longer chain hydrocarbon molecules maybe recycled back to the reaction chamber. In some implementations,distillation may not be necessary, and the fuel product only needs to befiltered.

In some configurations, it is desirable to control the processes of thereaction to allow a higher efficiency of fuel extraction from thefeedstock. FIG. 19B is a block diagram of a microwave sub-system (1905)that includes the sub-system components described in connection withFIG. 19A along with a feedback control system (1950). The illustratedfeedback control system 1950 includes a controller (1951) and one ormore sensors (1952), (1953), (1954) which may be configured to senseparameters at various stages during the process. Feedback control system1950 may include sensors 1952 at the feedstock preparation stage whichare configured to sense parameters of the feedstock and/or feedstockpreparation process. For example, sensors 1952, may sense the chemicalcomposition of the feedstock, density, moisture content, particle size,energy content or other feedstock parameters. Sensors 1952 mayadditionally or alternatively sense the conditions within the feedstockpreparation chamber, e.g., flow, pressure, temperature, humidity,composition of the gases present in the chamber, etc. Sensors 1952develop signals (1955 a) which are input to controller electronics 1951where they are analyzed to determine the condition of the feedstockand/or the feedstock preparation process. In response to sensed signals1955 a, controller 1951 develops feedback signals (1955 b) which controlthe operation of the feedstock preparation module (1913). For example,in some implementations, the controller 1951 may control feedstockpreparation module 1913 to continue to shred and/or grind the feedstockmaterial until a predetermined particle size and/or a predeterminedparticle size variation is detected. In another example, based on thesensed chemical composition of the feedstock, controller 1951 may causea greater or lesser amount of catalyst to be mixed with the feedstock ormay cause different types of catalyst to be mixed with the feedstock.

A control system (1950) may also develop feedback signals (1956 b),(1957 b) to control the operation of water extraction module 1920 and/orthe reaction module 1930, respectively, based on sensed signals 1956 a,1957 a. For example, the sensors (1953), (1954) may sense thetemperature of the water extraction and/or reaction processes andcontroller 1951 may develop feedback signals 1956 b, 1957 b to controlthe operation of heating/radiation systems 1922, 1932, e.g., power,frequency, pulse width, rotational or translational velocity, etc. ofone or both of magnetrons 1923, 1933. Controller 1051 may developfeedback signals to the magnetrons to control the amount of radiationimpinging on the feedstock so that the feedstock will not be over-cookedor under-cooked and development of hot spots will be avoided. Controllersystem 1950 may control the injection of various substances into one orboth of the extraction chamber and/or the reaction chamber 1921, 1931through the entry ports to control the processes taking place within thechambers 1921, 1931. Biochar, the residue of the depleted feedstock, issent to a storage unit. In some embodiments, controller system 1950 maybe used to control conditions that beneficially affect the properties ofthe processed biochar where specific properties are desired beyond thatresulting just from the feedstock choice. After the distillation stage,the heavy hydrocarbons may be recycled back into the reaction chamberand the lighter hydrocarbons may be sent on to a polymerization stage.

The reaction chambers may be made of quartz, glass, ceramic, plastic,and/or any other suitable material that is substantially transparent tomicrowaves in the frequency and energy range of the reaction processes.In some configurations, the heating/radiation systems described hereinmay include one or more magnetrons that rotate relative to the reactionchamber. In some embodiments, the magnetrons may be multiple and/or maybe stationary. FIG. 20A illustrates a reaction system (2000) whichincludes multiple stationary magnetrons (2011) arranged on a drum (2012)that acts as a Faraday cage and is disposed outside a cylindricalreaction chamber (2013) having one or more microwave-transparent walls.In reaction system 2000, the drums made of a material that is microwaveopaque, such as, for example, metal, so as to cause the microwaves inreaction chamber 2013 to reflect back and forth through the feedstock,thus more efficiently being used to convert the feedstock into liquidrenewable fuel and solid renewable fuel biochar. The operation of themagnetrons may be continuous, or may be pulsed, e.g., in a multiplexedpattern. In some embodiments (FIG. 20B), drum 2013 supporting magnetrons2011 may be rotated (2030) around the longitudinal axis (2050) ofreaction chamber 2012 and/or reaction chamber 2012 may be rotated (2020)around its longitudinal axis 2050.

A feedstock transport mechanism may be disposed within a reactionchamber. For example, as illustrated in FIG. 20C, the feedstocktransport mechanism may comprise one or more baffles (2061) that areconfigured to move the feedstock through a reaction chamber (2060) asthe reaction chamber rotates. The baffles 361 may be mounted to thewalls of reaction chamber 2060 and/or may be otherwise installed withinthe reaction chamber to provide movement of feedstock within and throughreaction chamber 2060, e.g., longitudinally through the reactionchamber.

In some embodiments, illustrated in FIG. 21, one or more secondary heatsources (2150), such as a flame, steam, and/or electric resistiveheating, or recycled heat, may be used in addition to magnetrons (2116)which are stationary, or are supported on a mechanism (2117) thatrotates around the circumference of the reaction chamber (2120) enclosedin a microwave-reflecting Faraday cage (2121). In some configurations,magnetrons 2116 may not make a complete revolution around reactionchamber 2120, but may rotate back and forth (2119) along an arc thatfollows the circumference of reaction chamber 2120. Variousconfigurations are possible as long as the feedstock is exposed tosubstantially uniform heat throughout the mass of the feedstockparticles to form processed biochar having pore density, distribution,and variance in size and distribution as described above for processedbiochar of the invention.

Movement of the one or more magnetrons relative to the reaction chambermay also include motion that moves the magnetron along the longitudinalaxis of the reaction chamber, as illustrated in FIG. 22. A reactionchamber (2210) and a cage (2220) are illustrated that support amagnetron (2230). Cage 2220 and magnetron 1330 may be moved (2240) backand forth along the longitudinal axis (2250) of reaction chamber 2210and over a metal microwave-reflecting Faraday cage (2215) enclosingreaction chamber 2210. In some implementations, in addition to and/orconcurrent with the motion (2240) of cage 2220 and magnetron 2230 alonglongitudinal axis 2250, cage 22320, and magnetron 2230 may be rotated(2260) around the longitudinal axis 2250.

Pelletizing/Blending Sub-System

The pelletizing sub-system is used to convert the processedorganic-carbon-containing feedstock from the beneficiation sub-systeminto the pellets suitable for use in a coal combustion apparatus such asmany electricity-producing power plants that combust coal or coal-likesolid fuels. The pelletizing sub-system comprises a compression chamberand a collection chamber. The a compression chamber is configured toseparate the processed organic-carbon-containing feedstock into discreteunits of mass having a longest length of at least 0.16 inch (0.41 cm)and a density of at least 37.5 pounds per cubic foot (0.60 grams percubic centimeter) to form processed biomass pellets. In some embodimentsthe compression is done under heat. In other embodiments, the slurry ofmicro particles and lignin from the reactor of the beneficiationsub-system, discussed above, is mixed with the processedorganic-carbon-containing feedstock before compression. This results inthe need for little if any heat or high energy biomass binder to formthe processed biomass pellets. The collection chamber is configured togather an aggregate of processed biomass pellets.

In some embodiments, the pelletizing sub-system further comprises aheating chamber configured to apply sufficient heat to the processedorganic-carbon-containing feedstock to reduce its water content to lessthan 10% by weight and form pellets. In some embodiments, thecompression chamber and the heating chamber are the same chamber.

In some embodiments, the pelletizing sub-system is used to prepare thecoal stream where the coal is a substituted processed biomass.

In some embodiments, a blending sub-system is also used where coal is ablend of coal and processed biomass. The blending sub-system is used tosize the coal particles, mix the coal particles with the processedbiomass, pulverize the blend, and compact the blend into high energyprocessed biomass/coal blended compact aggregate that, for example, aresuitable for use in a coal combustion apparatus such as anelectricity-producing power plant. The blending sub-system firstcomprises one or more sizing chambers to separately or together sizecoal and processed biomass into suitable sized particles for subsequentblending. Because and biomass powder have a potential to be explosive,chambers that handle them may have oxygen-deficient atmospheres. Anychunks of coal are reduced to the size of fines in an oxygen-deficientatmosphere, if necessary to prevent any danger of explosions. Similarsized particles of coal and processed biomass are easier to mix intosubsequent aggregates that are substantially uniform. In someembodiments a suitable size that balances cleanliness of the coal withloss of coal that is also separated out is on the order of particlesbeing able to pass through an 8 mesh size with square holes of 0.097inches (2.380 mm). Some embodiments have particles able to pass througha finer screen such as a 16 mesh screen with square holes of 0.0469inches (1.190 mm) on a side. Similarly, oxygen-deficient atmospheres areused in the blending system as needed to prevent explosions from highconcentrations of processed biomass and coal dust or fines. Next thesized particles of coal and processed biomass is combined in a blendingchamber that is configured to combine properly sized particles of highenergy coal with processed biomass into a blended powder of apredetermined ratio of high energy coal to processed biomass. Then theblend passes to a compacting chamber is configured to compress theblended powder into high energy blended compact aggregates. Finally, thehigh energy processed biomass/coal blended compact aggregate iscollected in a collection chamber. In some embodiments, the processedbiomass and coal are mixed and simultaneously sized and blended in adevice, such as for example, a high speed vortex in the blending andpulverizing unit followed by remixing as necessary with high energybiomass binder.

In some embodiments, the blending sub-system further comprises a heatingchamber configured to apply sufficient heat to the processedorganic-carbon-containing feedstock to reduce its water content to lessthan 10% by weight and to form the processed biomass/coal blendedcompact aggregates. In some embodiments, the compression chamber and theheating chamber are the same chamber.

In some embodiments, the vapor explosion section of the beneficiationsub-system further comprises a wash element that is configured to removeand clean micro particles of unprocessed organic-carbon-containingfeedstock, lignin fragments, and hemicellulosic fragments from the vaporexplosion section into a fine, sticky mass of biomass with high lignincontent that is a high energy processed biomass binder. In thisembodiment, the blending chamber of the blending subsection is furtherconfigured to receive the high energy binder to permit at least one oflower temperatures or less if any additional high energy processedbiomass binder content in a compaction chamber formation duringformation of blended compact aggregates. In another embodiment, anotherbinder such as corn starch may be added in lieu of or in combinationwith the high lignin micro particles from the vapor explosion section tothe compression chamber to lower the temperature needed to produceviable pellets.

FIG. 23 is a diagram of a system to make processed biomass made fromunprocessed organic-carbon-containing feedstock and co-fire them withcoal in a coal combustion apparatus with the addition of micro particleand lignin slurry that is optional. In this embodiment the coal isreplaced with a blended compact aggregate of coal and processed biomass.In this embodiment, the unprocessed organic-carbon-containing feedstock,untreated biomass input, is sized (2310), then passed throughbeneficiation reaction chamber where the fibers are disrupted (2320),the salt is solubilized and the feedstock is then washed (2330). Duringfiber disruption 2330, the effluent containing micro particles andlignin is removed (2340), washed and introduced to the processedorganic-carbon-containing feedstock in a remixing step (2360) after theprocessed organic-carbon-containing feedstock has gone through adewatering and desolvating step (2350) to become processed biomass. Atleast some of it then passes through a pelletizing sub-system (2351) tobecome processed biomass pellets that are sent to a second chamber(2390) of a coal combusting apparatus at some later time. Coal and coaldust or fines (2352) is sized similar to the size of the processedbiomass particles (2354), blended with additional processed biomass in ablending and pulverizing unit (2356), and remixed (2360) as necessarywith high energy biomass binder. The mixture is then compacted in toaggregates or briquettes (2370) and collected (2380) to be sent to afirst chamber (2385) of a coal combusting apparatus at some later time.The use of the washed effluent stream of high energy sticky biomass mayalso serve to reduce the need for heat to form the blended aggregates ina cold pressing pelletizing/briquetting scheme although heat still maybe advantageous to remove additional water or to form a more viablebriquette or pellet in some embodiments.

Gas Separation Sub-System and Consumption Sub-System

While many of the adverse gaseous byproducts found in typical coalcombustion systems are removed in the system of our invention because ofcleaner biomass diluents of or substituted for the bulk of coal, somesuch as carbon dioxide gas and carbon monoxide gas remain. Of the two,carbon dioxide is in the greater concentration in the gaseous wastestream of a coal combustion apparatus. Part of the atmosphere andconsidered for many years to be harmless, in recent years carbon dioxidehas become associated with green house global warming when concentrations become excessive. Economical technologies are needed to both separatethe gas from the gaseous waste streams after coal combustion, such as inpassage ways leading to exhaust stacks or in the exhaust stacks beforethe gases reach the open atmosphere. In addition, economicaltechnologies are needed to consume the isolated gases so that they areno longer free to enter the atmosphere and adversely contribute toglobal warming by raising global carbon dioxide levels in the atmosphereabove safe levels.

In recent years means have been developed for separating and consumingwaste gases such as the carbon dioxide from the exhaust streams that areproduced in the coal consumption apparatus. The waste gas separationsub-system involves at least one exhaust chamber in the coal combustionapparatus having a gaseous waste stream and comprises at least one gasseparation sub-system configured to separate at least 50 volume % ofcarbon dioxide from the gaseous waste stream. Some embodiments involveremoving the carbon dioxide directly from the exhaust stream flue gasand others involve removing the carbon dioxide through air capture. Aircapture is the removal of carbon dioxide from an exhaust stream that hasbeen cooled and diluted. Global Thermostat allows air capture, thepulling out of carbon dioxide from an air stream rather than an exhauststream from a coal consumption apparatus. The technology uses low-costleft over process heat as energy for the capture of carbon dioxide fromthe atmosphere. Since energy typically accounts for over two-thirds thetotal operating cost of competing carbon capture technologies, thistechnology dramatically lowers the cost of reducing carbon emissions.When process heat is used, the current paradigm(more-energy-equals-more-emissions) reverses and the more energyproduced means more carbon reduced. Air capture is different from otherforms of carbon capture in that it extracts carbon dioxide directly fromthe atmosphere. Other carbon capture technologies typically extractcarbon dioxide from flue gases. The air capture process is known andrequires separating carbon from ambient air, at low temperatures, and ata concentration of about 400 parts per million, as opposed to hightemperatures and 15,000 parts in the case of flue gas. Compared withflue gas extraction, the air capture with Global Thermostat's technologyhas multiple advantages including lower costs, proven processes, higherpurity of carbon dioxide gas, extraction at lower concentrations, andmore flexibility in location.

The consumption sub-system includes a carbon dioxide gas consumptionsub-system configured to receive the separated carbon dioxide gas andconsume it in the forming of useful materials. Embodiments may make useof several technologies are suitable for the consumption sub-system.Some embodiments use the encapsulation of separated carbon dioxide inplastic or the insertion into cement. Another embodiment involves theconversion of carbon dioxide into useful chemicals. Liquid Light hasdeveloped technology that allows carbon dioxide to be converted withlow-energy catalytic electrochemistry into beneficial industrialchemicals such as glycols, alcohols, olefins, and organic acids. Theprocess combines carbon dioxide with water, natural gas or wastes suchas, for example, process water, shale gas, and smokestack acids, andclean energy such as, for example, the waste heat of energy conversionunits such as boilers that are typically 40-60% efficient. Additionally,by using co-feedstock along with carbon dioxide, a plant built with thistechnology is able to produce multiple products simultaneously. Anotherexample of a consumption technology is the encapsulation of separatedcarbon dioxide in plastic or stored in cement.

FIG. 23A depicts a diagram of the system shown in FIG. 23 showing thecoal combustion apparatus with the gas separation sub-system and theconsumption sub-system for the removal of carbon dioxide from the gaswaste stream of the apparatus. In this embodiment, the pulverized coalcontaining or coal substituted feedstock in the first chamber (2385) andthe pulverized processed biomass from the second chamber (2390) arepassed to a coal combustion apparatus (2392) that converts water to asteam (2393) used for generating power and emit a gaseous waste (2394).Gaseous waste 2394 passes through a gas separation sub-system (2396) toremove at least 50 volume % of carbon dioxide from the gaseous wastestream. Separated carbon dioxide is then passed through a consumptionsub-system (2398) to be used in the making of materials such as, forexample, encapsulated plastics, cement, or specific chemicals,

Processes

The invention also comprises a process for making a processedbiomass/coal blended compact aggregate that comprises at least 10 wt %of a coal having an energy density of at least 21 MMBTU/ton (24 GJ/MT)and at least 10 wt % of a processed biomass comprises three steps. Thefirst step is to input into a system comprising a first, a second, and athird subsystem components comprising coal and a renewable, unprocessedorganic-carbon-containing feedstock that includes free water,intercellular water, intracellular water, intracellular water-solublesalts, and at least some plant cells comprising cell walls that includelignin, hemicellulose, and microfibrils within fibrils. The second stepis to pass unprocessed organic-carbon-containing feedstock through abeneficiation sub-system process to result in processed biomass having awater content of less than 20 wt % and a water soluble intracellularsalt content that is reduced by at least 60 wt % on a dry basis for theprocessed organic-carbon-containing feedstock from that of theunprocessed organic-carbon-containing feedstock. The third step is topass the processed biomass through a blending sub-system process, to bejoined with coal to result in a processed biomass/coal blended compactaggregate that comprises at least 10 wt % of a coal having an energydensity of at least 21 MMBTU/ton (24 GJ/MT) and at least 10 wt % of aprocessed biomass comprising a processed organic-carbon-containingfeedstock with characteristics that include an energy density of atleast 17 MMBTU/ton (20 GJ/MT) and a water-soluble intracellular saltcontent that is decreased more than 60 wt % on a dry basis for theprocessed organic-carbon-containing feedstock from that of unprocessedorganic-carbon-containing feedstock that was the source of the processedorganic-carbon-containing feedstock. Some embodiments augment theprocess by using a heating sub-system process to make a processedbiomass that is a processed biochar having an energy density of at least21 MMBTU/ton (24 GJ/MT).

The process includes two aspects of the beneficiation process for makingprocessed carbon-containing feedstock with the beneficiation sub-systemdiscussed above and four aspects of the heating sub-system, threeaspects of the oxygen-deficient thermal process for converting theprocessed carbon-containing feedstock into processed biochar and oneaspect of a microwave process for converting the processedcarbon-containing feedstock into processed biochar.

Beneficiation Sub-System Process

The beneficiation process step comprises the step of passing unprocessedorganic-carbon-containing feedstock through a beneficiation sub-systemprocess to result in processed organic-carbon-containing feedstockhaving a water content of less than 20 wt % and a salt content that isreduced by at least 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of the unprocessedorganic-carbon-containing feedstock that was the source of the processedorganic-carbon-containing feedstock. There are two aspects of thebeneficiation sub-system process. The first focuses on the properties ofthe processed organic-carbon-containing feedstock and the second focuseson the energy efficiency of the process of the invention over that ofcurrently known processes for converting unprocessedorganic-carbon-containing feedstock into processedorganic-carbon-containing feedstock suitable for use with downstreamfuel producing systems. Both use the beneficiation sub-system disclosedabove.

First Aspect

The first aspect of the beneficiation process step of the inventioncomprises four steps. The first step is inputting into a reactionchamber unprocessed organic-carbon-containing feedstock comprising freewater, intercellular water, intracellular water, intracellularwater-soluble salts, and at least some plant cells comprising cell wallsthat include lignin, hemicellulose, and microfibrils within fibrils.Some embodiments have unprocessed organic-carbon-containing feedstockthat comprises water-soluble salts having a content of at least 4000mg/kg on a dry basis.

The second step is exposing the feedstock to hot solvent under pressurefor a time at conditions specific to the feedstock to make at least someregions of the cell walls comprising crystallized cellulosic fibrils,lignin, and hemicellulose more able to be penetrable by water-solublesalts without dissolving more than 25 percent of the lignin andhemicellulose. As mentioned above, this is accomplished by one or moreof unbundling regions of at least some fibrils, depolymerizing at leastsome strands of lignin and/or hemicellulose, or detaching them from thecellulose fibrils, thereby disrupting their interweaving of the fibrils.In addition, the cellulose fibrils and microfibrils can be partiallydepolymerized and/or decrystallized.

The third step is rapidly removing the elevated pressure so as topenetrate the more penetrable regions with intracellular escaping gasesto create porous feedstock with open pores in at least some plant cellwalls. In some embodiments the pressure is removed to about atmosphericpressure in less than 500 milliseconds (ms), less than 300 ms, less than200 ms, less than 100 ms, or less than 50 ms.

The fourth step is pressing the porous feedstock with conditions thatinclude an adjustable compaction pressure versus time profile andcompaction time duration, and between pressure plates configured toprevent felt from forming and blocking escape from the reaction chamberof intracellular and intercellular water and intracellular water-solublesalts, and to create processed organic-carbon-containing feedstock thathas a water content of less than 20 wt % and a water-soluble saltcontent that is decreased by at least 60% on a dry basis that of theunprocessed organic-carbon-containing feedstock. In some embodiments,the water content is measured after subsequent air-drying to removeremaining surface water. In some embodiments, the pressure plate has apattern that is adapted to particular organic-carbon-containingfeedstock based on its predilection to form felts and pith content asdiscussed above. In some embodiments, the pressure amount and pressureplate configuration is chosen to meet targeted processedorganic-carbon-containing feedstock goals for particular unprocessedorganic-carbon-containing feedstock. In some embodiments, the pressureis applied in steps of increasing pressure, with time increments ofvarious lengths depending on biomass input to allow the fibers to relaxand more water-soluble salt to be squeezed out in a more energyefficient manner. In some embodiments, clean water is reintroduced intothe biomass as a rinse and to solubilize the water-soluble slats beforethe fourth step begins.

The process may further comprise a fifth step, prewashing theunprocessed organic-carbon-containing feedstock before it enters thereaction chamber with a particular set of conditions for eachorganic-carbon-containing feedstock that includes time duration,temperature profile, and chemical content of pretreatment solution to atleast initiate the dissolution of contaminates that hinder creation ofthe cell wall passageways for intracellular water and intracellularwater-soluble salts to pass outward from the interior of the plantcells.

The process may further comprise a sixth step, masticating. Theunprocessed organic-carbon-containing feedstock is masticated intoparticles having a longest dimension of less than 1 inch (2.5centimeters) before it enters the reaction chamber.

The process may further comprise a seventh step, separating out thecontaminants. This step involves the separating out of at least oils,waxes, and volatile organic compounds from the porous feedstock withsolvents less polar than water.

As with the system aspect, the unprocessed organic-carbon-containingfeedstock may comprise at least two from a group consisting of anherbaceous plant material, a soft woody plant material, and a hard woodyplant material that are processed in series or in separate parallelreaction chambers. In addition, in some embodiments, the energy densityof each plant material in the processed organic-carbon-containingfeedstock may be substantially the same. In some embodiments, theorganic-carbon-containing feedstock comprises at least two from thegroup consisting of an herbaceous plant material, a soft woody plantmaterial, and a hard woody plant material, and wherein the energydensity of each plant material in the processedorganic-carbon-containing feedstock is at least 17 MMBTU/ton (20 GJ/MT).

FIG. 24 is a block diagram of a process for making processedorganic-carbon-containing feedstock with less than 60 percentwater-soluble salt on a dry basis over that of its unprocessed form andwith less than 20 wt % water. Step 2410 involves inputting unprocessedorganic-carbon-containing feedstock that has at least some plant cellsthat include intracellular water-soluble salt and cell walls comprisinglignin into a reaction chamber. Step 2420 involves exposing thefeedstock to hot solvent under pressure for a time to make some regionsof the cell walls comprising crystallized cellulosic fibrils, lignin,and hemicellulose more able to be penetrable by water-soluble saltswithout dissolving more than 25 percent of the lignin andhemicelluloses. Step 2430 involves removing the pressure so as topenetrate at least some of the cell walls so as to create porousfeedstock with open pores in its plant cell walls. Step 2440 involvespressing the porous feedstock with a plate configured to prevent feltfrom blocking escape of intracellular water and intracellularwater-soluble salts from the reaction chamber so as to create processedorganic-carbon-containing feedstock that has a water content of lessthan 20 wt % and a water-soluble salt content that is decreased by atleast 60 wt % on a dry basis for the processed organic-carbon-containingfeedstock from that of unprocessed organic-carbon-containing feedstockthat was the source of the processed organic-carbon-containingfeedstock.

Second Aspect

The second aspect is similar to the first except steps have anefficiency feature and the resulting processed organic-carbon-containingfeedstock has a cost feature. The second aspect also comprises foursteps. The first step is inputting into a reaction chamberorganic-carbon-containing feedstock comprising free water, intercellularwater, intracellular water, intracellular water-salts, and at least someplant cells comprising lignin, hemicellulose, and fibrils within fibrilbundles. Each step emphasizes more specific conditions aimed at energyand material conservation. The second step is exposing the feedstock tohot solvent under pressure for a time at conditions specific to thefeedstock to swell and unbundle the cellular chambers comprisingpartially crystallized cellulosic fibril bundles, lignin, hemicellulose,and water-soluble salts without dissolving more than 25 percent of thelignin and to decrystallize at least some of the cellulosic bundles. Thethird step is removing the pressure to create porous feedstock with openpores in its cellulosic chambers. After possibly mixing with fresh waterto rinse the material and solubilize the water-soluble salts, the fourthstep is pressing the porous feedstock with an adjustable compactionpressure versus time profile and compaction duration between pressureplates configured to prevent felt from forming and blocking escape fromthe reaction chamber of intracellular and intercellular water andintracellular water-soluble salts, and to create a processedorganic-carbon-containing feedstock that has a water content of lessthan 20 wt %, a water-soluble salt content that is decreased by at least60 wt % on a dry basis, and a cost per weight of removing the water andthe water-soluble salt is reduced to less than 60% of the cost perweight of similar water removal from known mechanical, knownphysiochemical, or known thermal processes.

FIG. 25 is a block diagram of a process for making processedorganic-carbon-containing feedstock with less than 50 wt % water-solublesalt of a dry basis than that of unprocessed organic-carbon-containingfeedstock and less than 20 wt % water, and at a cost per weight of lessthan 60% that of similar water removal from known mechanical, knownphysiochemical, or known thermal processes that can remove similaramounts of water and water-soluble salt. Step 2510 involves inputtingunprocessed organic-carbon-containing feedstock that has at least plantcells comprising intracellular water-soluble salts and plant cell wallsthat include lignin into a reaction chamber. Step 2520 involves exposingthe feedstock to hot solvent under pressure for a time to make someregions of the cell walls comprising of crystallized cellulosic fibrils,lignin, and hemicellulose more able to be penetrable by water-solublesalts without dissolving more than 25 percent of the lignin andhemicelluloses. Step 2530 involves removing the pressure so as topenetrate at least some of the cell walls to create porous feedstockwith open pores in its plant cell walls. Step 2540 involves pressing theporous feedstock with a plate configured to prevent felt from blockingescape of intracellular water and intracellular water-soluble salts fromthe reaction chamber so as to create processed organic-carbon-containingfeedstock that has a water content of less than 20 wt %, a water-solublesalt content that is decreased by at least 60 wt % on a dry basis overthat of the unprocessed organic-carbon-containing feedstock, and a costper weight of removing the water and water-soluble salt that is reducedto less than 60% of the cost per weight of similar water removal fromknown mechanical, physiochemical, or thermal processes.

Energy efficiencies are achieved in part by tailoring process conditionsto specific organic-carbon-containing feedstock as discussed above. Someembodiments use systems engineered to re-capture and reuse heat tofurther reduce the cost per ton of the processedorganic-carbon-containing feedstock. Some embodiments remove surface orfree water left from the processing of the organic-carbon-containingfeedstock with air drying, a process that takes time but has noadditional energy cost. FIG. 26 is a table that shows some processvariations used for three types of organic-carbon-containing feedstocktogether with the resulting water content and water-soluble salt contentachieved. It is understood that variations in process conditions andprocessing steps may be used to raise or lower the values achieved inwater content and water-soluble salt content and energy cost to achievetargeted product values. Some embodiments have achieved water contentsas low as less than 5 wt % and water-soluble salt contents reduced by asmuch as over 95 wt % on a dry basis from its unprocessed feedstock form.

Oxygen-Deficient Thermal Sub-system Process

The oxygen-deficient thermal sub-system process step comprises passingthe processed organic-carbon-containing feedstock through anoxygen-deficient sub-system process to result in a solid fuelcomposition having an energy density of at least 17 MMBTU/ton (20 GJ/MT)a water content of less than 10 wt %, and a water-soluble salt that isdecreased by at least 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of the unprocessedorganic-carbon-containing feedstock.

In the broadest perspective the process comprises three steps. The firststep is to input into a system, comprising a first and a secondsubsystem, an unprocessed organic-carbon-containing feedstock thatincludes free water, intercellular water, intracellular water,intracellular water-soluble salts, and at least some plant cellscomprising cell walls that include lignin, hemicellulose, andmicrofibrils within fibrils. The second step is to pass the unprocessedorganic-carbon-containing feedstock through the first sub-system, abeneficiation sub-system process, to result in processedorganic-carbon-containing feedstock having a water content of less than20 wt % and a salt content that is reduced by at least 60 wt % on a drybasis for the processed organic-carbon-containing feedstock from that ofthe unprocessed organic-carbon-containing feedstock. The third step isto pass the processed organic-carbon-containing feedstock through thesecond sub-system, an oxygen-deficient thermal sub-system process, toresult in a solid fuel composition having an energy density of at least17 MMBTU/ton (20 GJ/MT) a water content of less than 10 wt %, andwater-soluble salt that is decreased by at least 60 wt % on a dry basisfor the processed organic-carbon-containing feedstock from that of theunprocessed organic-carbon-containing feedstock.

The process that uses the horizontal oxygen-deficient thermal sub-systeminvolves four steps. The first step is to input processedorganic-carbon-containing feedstock into a substantially horizontalsublimating reaction chamber largely contained within a hot box. Thereaction chamber is configured to be able to (1) heat from an ambienttemperature to an operating sublimation temperature, (2) operate at asublimation temperature, and (3) cool from an operating sublimationtemperature to an ambient temperature. This is done without leaking anyhot product gas fuel from the reaction chamber into the hot box oratmosphere, or leaking any oxygen from outside the hot box into the hotbox. The second step is to heat the processed organic-carbon-containingfeedstock to a sublimating temperature before it is able to form aliquid phase. The third step is to maintain the temperature at asublimation temperature for a residence time that is as long a time asneeded to convert the processed organic-carbon-containing feedstock toprocessed biogas and processed biochar. The fourth step is to separatethe processed biogas from the processed biochar.

These steps are depicted in FIG. 27, a flow diagram of the process forgenerating processed biochar from processed organic-carbon-containingfeedstock in accordance with embodiments of the invention. In 2710 theprocessed organic-carbon-containing feedstock is inputted into ahorizontal sublimating reaction chamber contained within a hot boxwithout leaking any hot product gas fuel from the reaction chamber intothe hot box or atmosphere, or leaking any oxygen from outside the hotbox into the hot box. Next, in step 2720, the processedorganic-carbon-containing feedstock is heated to a sublimatingtemperature before it is able to form a liquid phase. In step 2730, thetemperature is maintained at a sublimation temperature for a residencetime that is as long a time as is needed to convert the processedorganic-carbon-containing feedstock to processed biogas fuel andprocessed biochar fuel. Finally, in step 2740 the product gas fuel andthe processed biochar fuel are separated from each other.

In some embodiments the process may use a horizontal sublimationsub-system, depending on its size, wherein the substantially horizontalsublimating reaction chamber is supported by a vertical support. It isbeneath the substantially horizontal reaction chamber. It is alsoconfigures to be dimensionally stable in the vertical direction overtemperature variations of from ambient temperature to about 850° C. thatmay occur during the startup, operating, and shutdown operations of thesubstantially horizontal reaction chamber.

The process that uses the vertical oxygen-deficient thermal sub-systeminvolves four steps. This is depicted in FIG. 28. In 2810, the firststep is to input processed organic-carbon-containing feedstock into asubstantially vertical sublimating reaction chamber. In 2820, the secondstep is to heat the processed organic-carbon-containing feedstock to asublimating temperature before it is able to form a liquid phase. In2830, the third step is to maintain the temperature at a sublimationtemperature for a residence time that is as long a time as is needed toconvert the processed organic-carbon-containing feedstock to processedbiogas and processed biochar. In 2840, the fourth step is to separatethe processed biogas from the processed biochar.

Microwave Sub-System Process

The microwave sub-system process step comprises passing the processedorganic-carbon-containing feedstock through a microwave sub-systemprocess to result in a solid renewable fuel composition having an energydensity of at least 17 MMBTU/ton (20 GJ/MT) a water content of less than10 wt %, water-soluble salt that is decreased by at least 60 wt % on adry basis for the processed organic-carbon-containing feedstock fromthat of the unprocessed organic-carbon-containing feedstock, and poresthat have a variance in pore size of less than 10%.

FIG. 29 is a block diagram of an embodiment of a process for passingprocessed organic-carbon-containing feedstock through a microwavesub-system to create a solid renewable fuel processed biochar of theinvention. The processed organic-carbon-containing feedstock is input(2910) to a reaction chamber having walls that are substantiallytransparent to microwaves used to heat and/or irradiate the feedstock.The heating and/or radiation occur by directing (2920) the microwaveenergy through the walls of the reaction chamber so that it impinges onthe feedstock disposed within the reaction chamber. The feedstock isheated/irradiated (2930) by the microwaves, optionally in the presenceof a catalyst, until reaction of the organic-carbon-containing moleculesoccurs to produce the desirable end fuel product. The fuel productcreated by the reaction processes are collected (2940).

Pelletizing/Blending Sub-System Process

The pelletizing sub-system process step comprises two steps. The firststep is compressing the processed biomass to separate it into pelletswith discrete units of mass having a longest length of at least 0.16inch (0.41 cm), a diameter of less than 0.25 inch (6 mm), and a densityof at least 37.5 pounds per cubic foot (0.60 grams per cubiccentimeter). The second step is collecting the aggregate of pellets. Insome embodiments the compression is done under heat to at least assistthe formation of aggregates or reduce the content of water to less than10% by weight. In some embodiments, the steps of compression and heatingare done at the same time. In some embodiments, the beneficiationsub-system process further comprises removing and cleaning of microparticles of unprocessed organic-carbon-containing feedstock, ligninfragments, and hemicellulosic fragments from the vapor explosion sectioninto a high energy biomass binder, a fine, sticky mass of biomass withhigh lignin content, in the removing the pressure step, and the blendingsub-system further comprises adding the high energy biomass binder tothe blended powder to permit lower temperatures or more cohesiveness inthe compressing step during formation of blended compact aggregates.

In some embodiments, the pelletizing sub-system is used to prepare thecoal stream where the coal is a substituted processed biomass.

In some embodiments a blending sub-system process is also used where thecoal comprises a blend of coal and processed biomass. Less energy isconsumed in the pulverizing of the coal at a coal-firing apparatus wherethe coal is composes of aggregates of components that have already beenpulverized before aggregation. The blending sub-system process stepcomprises three steps. When handling coal dust, fines, or powder, anoxygen-deficient atmosphere may be employed to minimize the occurrenceof explosions.

The first step is a sizing step to reduce the size of the particles ofcoal and processed biomass to one that permits easy subsequent mixing.Any coal chunks present are reduced to the size of coal dust or coalfines for easy transport into the blending process. In some embodiments,the processed biomass and coal are mixed and simultaneously sized andblended in a high speed vortex in the blending and pulverizing unit. Insome embodiments a suitable size is on the order of particles being ableto pass through an 8 mesh size with square holes of 0.097 inches (2.380mm). Some embodiments have particles able to pass through a finer screensuch as a 16 mesh screen with square holes of 0.0469 inches (1.190 mm)on a side. With some studies using magnetic fields, half of theimpurities were be removed from coal with the removal of less than 5 wt% of the carbon in the coal for coal sized to pass through an 16 meshscreen.

The second step is a combining step to combine both the coal and theprocessed biomass into a blended powder of a predetermined ratio of coalto processed biomass. In some embodiments, a high energy biomass binderis added. The high energy biomass binder is formed in the beneficiationsub-system process, discussed above, with the removing and cleaning ofmicro particles of unprocessed organic-carbon-containing feedstock,lignin fragments, and hemicellulosic fragments from the vapor explosionsection. The high energy biomass binder, a fine, sticky mass of biomasswith high lignin content, is then added to the blended powder to permitat least one of lower temperatures or more cohesiveness in thecompressing step during formation of blended compact aggregates.

The third step is compressing the blended powder into a multitude ofblended compact aggregates that are safe for transport. In someembodiments the compression is done under heat to at least assist theformation of aggregates or reduce the content of water to less than 10%by weight. In some embodiments, the steps of compression and heating aredone at the same time.

Gas Separation Sub-System and Consumption Sub-System Process

As stated above, many of the adverse gaseous byproducts found in typicalcoal combustion systems are removed in the system of the inventionbecause of cleaner biomass diluents of or substituted for the bulk ofcoal. One of the major remaining adverse materials is carbon dioxide gasin the gaseous waste stream of the coal combusting apparatus.

The gas separation sub-system process for separating carbon dioxide fromthe exhaust stream has several steps. Inputting at least one exhaustchamber having a gaseous waste stream and comprising at least one carbondioxide gas separator sub-system configured to separate at least 50volume % of carbon dioxide from the gaseous waste stream;

-   -   a carbon dioxide gas consumption sub-system configured to        receive the separated carbon dioxide gas and consume it in        useful materials;

The first step is to cool the exhaust stream a low temperature and adddilute the exhaust stream with air to reduce the carbon dioxideconcentration to less than 1000 ppm in a cooled gas stream. The secondstep is to apply the proprietary process of Global Thermostat toseparating out the carbon dioxide from the cooled gas stream to formseparated carbon dioxide.

The consumption sub-system process for consuming the carbon dioxideinvolves two steps. The first step is to input the separated carbondioxide as feedstock into a carbon dioxide consumption sub-system withadditional feedstock comprising catalysts and co-reactants such aswater, natural gas and stack acids. The second step is to expose thefeedstock under heat from the waste heat from the coal consumptionapparatus to catalytic electrochemistry to create beneficial industrialchemicals such as glycols, alcohols, olefins, and organic acids.Alternatively the consumption sub-system process involves placing theseparated carbon dioxide into capturing vessels such as cement orencapsulating plastics for beneficial uses.

Various modifications and additions can be made to the preferredembodiments discussed hereinabove without departing from the scope ofthe present invention. Accordingly, the scope of the present inventionshould not be limited by the particular embodiments described above, butshould be defined only by the claims set forth below and equivalentsthereof.

What is claimed is:
 1. A coal combusting system for combusting coal in acoal combusting apparatus with less adverse by-products, comprising: afirst input chamber of a coal combusting apparatus configured topulverize coal and feed it into the coal combusting apparatus in a firstconcentration of feedstock; a second input chamber of the coalcombusting apparatus configured to pulverize processed biomass pelletsfrom a processed biomass system and feed it into the coal combustingapparatus in a second concentration of feedstock with the ratio of thefirst concentration to the second concentration between 1 to 9 and 9 to1; at least one exhaust chamber having a gaseous waste stream andcomprising at least one gas separation sub-system configured to separateat least 50 volume % of carbon dioxide from the gaseous waste stream; aconsumption sub-system configured to receive the separated carbondioxide gas and consume it in the making of useful materials; and theprocessed biomass system is configured to make processed biomass fromunprocessed organic-carbon-containing feedstock that includes freewater, intercellular water, intracellular water, intracellularwater-soluble salts, and at least some plant cells comprising cell wallsthat include lignin, hemicellulose, and microfibrils within fibrils, theprocessed biomass system, comprising: a. a beneficiation sub-systemconfigured to convert the unprocessed organic-carbon-containingfeedstock into a processed organic-carbon-containing feedstock withcharacteristics that include having an energy density of at least 17MMBTU/ton (20 GJ/MT), a water content of less than 20 wt %, and awater-soluble intracellular salt content that is decreased more than 60wt % on a dry basis from that of the unprocessedorganic-carbon-containing feedstock, and b. a pelletizing sub-system toconvert the processed organic-carbon-containing feedstock into processedbiomass pellets.
 2. The coal combusting system of claim 1 wherein thecoal is a coal substitute from the group consisting of a processedbiomass pellet or a coal aggregate that comprises a blend of coal andprocessed biomass, the coal aggregate is made in a blending sub-system,the blending sub-system, comprises: a sizing chamber to properly sizedparticles of coal and processed biomass to a similar size, a combiningchamber configured to blend the similarly sized particles into a blendedpowder of a predetermined ratio of coal to processed biomass, and acompacting chamber to compress the blended powder into blended compactaggregates; and the pelletizing sub-system, comprises: a compressionchamber configured to separate the processed organic-carbon-containingfeedstock into discrete units of mass having a longest length of atleast 0.16 inch (0.41 cm) and a density of at least 37.5 pounds percubic foot (0.60 grams per cubic centimeter) to form processed biocharpellets, and a collection chamber configured to gather aggregates ofprocessed biochar pellets.
 3. The coal combusting system of claim 1wherein the first input chamber of the coal combusting apparatus and thesecond input chamber of the coal combusting apparatus are the same inputchamber.
 4. The coal combusting system of claim 2 wherein the processedbiomass is processed biochar, the blended compact aggregate has anenergy density of at least 21 MMBTU/ton (25 GJ/MT), the processedorganic-carbon-containing feedstock is passed through a heatingsub-system to form processed biochar that is blended with coal into ablended compact aggregate in a blending sub-system, and thewater-soluble intracellular salt content decrease is based on comparingthe processed organic-carbon-containing feedstock before it is passedthrough the heating sub-system to the unprocessedorganic-carbon-containing feedstock.
 5. The coal combusting system ofclaim 2 wherein the beneficiation sub-system, comprises: a. atransmission device configured to convey into a reaction chamberunprocessed organic-carbon-containing feedstock comprising free water,intercellular water, intracellular water, intracellular water-solublesalts, and at least some plant cells comprising cell walls that includelignin, hemicellulose, and microfibrils within fibrils; b. at least onereaction chamber comprising at least one entrance passageway, at leastone exit passageway for fluid, at least one exit passageway forprocessed organic-carbon-containing feedstock, and at least threesections, the sections comprising, i. a wet fibril disruption sectionconfigured to interact with at least some of the lignin andhemicellulose between the fibrils to make at least some regions of thecell wall more susceptible to penetration by water-soluble salts withoutdissolving more than 25 percent of the lignin and hemicellulose, ii. avapor explosion section in communication with the wet fibril disruptionsection and at least configured to volatilize plant fibril permeablefluid through rapid decompression to penetrate the more susceptibleregions of the cell wall so as to create a porousorganic-carbon-containing feedstock with plant cell wall passageways forintracellular water and intracellular water-soluble salts to pass fromthe plant cell, and iii. a compaction section in communication with thevapor explosion section and configured to compress the porousorganic-carbon-containing feedstock between pressure plates configuredto minimize formation of water-impermeable felt so as to permit theescape of intracellular water and intracellular water-soluble salt fromthe reaction chamber fluid exit passageway and to create processedorganic-carbon-containing feedstock that passes out through its reactionchamber exit passageway; and c. a collection device in communicationwith the reaction chamber and configured to gather the processedorganic-carbon-containing feedstock having a water content of less than20% by weight, a combined lignin and hemicellulose content that isdecreased by at less than 25% on a dry basis from that of theunprocessed organic-carbon-containing feedstock, and a water-solubleintracellular salt content that is decreased by at least 60% on a drybasis from that of the unprocessed organic-carbon-containing feedstock.6. The coal combusting system of claim 4 wherein the heating sub-systemis an oxygen-deprived thermal sub-system, comprises: a reaction chamberconfigured to heat processed organic-carbon-containing feedstock in anatmosphere that contains less than 4 percent oxygen to a temperaturesufficient to convert at least some processed organic-carbon-containingfeedstock into processed biogas and processed biochar.
 7. The coalcombusting system of claim 6 wherein the oxygen-deprived thermalsub-system is from a group consisting of a. a substantially horizontalsublimation system, comprising: i. a hot box configured to be able toheat from an ambient temperature to an operating sublimationtemperature, maintain an initial operating sublimation temperature and afinal operating sublimation temperature that are stable within less than±10° C., and cool from operating sublimation temperatures to an ambienttemperature without leaking any oxygen into the hot box and having atleast one heat source in communication with the interior of the hot boxto supply heat as needed; ii. at least one substantially horizontalreaction chamber largely located within the hot box, having a surface,configured to heat the processed organic-carbon-containing feedstockwithout external catalyst or additional water to an operatingsublimation temperature in a time frame that is short enough to sublimeat least part of the processed organic-carbon-containing feedstockwithout creating substantially any liquid, configured to heat from anambient temperature to an operating sublimation temperature, operate ata sublimation temperature, and cool from a operating sublimationtemperature to an ambient temperature without leaking any product gasfuel into the surrounding hot box, and comprising an input end outsidethe hot box and configured to receive compressed feedstock through aninput line and an output end outside the hot box and configured todischarge product gas fuel gas through a discharge line and solid charfuel through an output line; ii. a first powered transport mechanismthat is located within the reaction chamber and is configured to conveysublimation products of the processed organic-carbon-containingfeedstock through the reaction chamber as the processedorganic-carbon-containing feedstock is transformed into processed biogasand processed biochar; and iv. a gas-tight element on both the inputline and output line and configured to prevent hot biogas from adverselyescaping from the reaction chamber; or b. a substantially verticalsublimation system, comprising: i. at least one substantially verticalreaction chamber configured to heat the processedorganic-carbon-containing feedstock without external catalyst oradditional water, carbon dioxide, or carbon monoxide, to an operatingsublimation temperature in a time frame that is short enough to sublimeat least part of the processed organic-carbon-containing feedstockwithout creating substantially any liquid; ii. a first powered transportmechanism that is located partly within the reaction chamber, has anextended part that extends outside the reaction chamber, and isconfigured to convey sublimation products of the processedorganic-carbon-containing feedstock through the reaction chamber as theprocessed organic-carbon-containing feedstock is transformed into biogasand processed biochar; and iii a self-adjusting seal that is configuredto continuously contain the processed biogas within the reaction chamberat the region surrounding the extended part of the powered transportmechanism during changing temperatures of startup and shutdownoperations, and during steady-state sublimation temperature duringoperation.
 8. The coal combusting system of claim 4 wherein the heatingsub-system is a microwave sub-system, comprising: a. at least onereaction chamber within a microwave reflecting enclosure, the reactionchamber comprising at least one microwave-transparent chamber wall andat least one reaction cavity within the reaction chamber that isconfigured to hold the organic-carbon-containing feedstock in anexternally supplied oxygen free atmosphere; b. a microwave subsystemcomprising at least one device configured to emit microwaves whenenergized, the microwave device positioned relative to the reactionchamber so that the microwaves are directed through themicrowave-transparent chamber wall and into the reaction cavity; and c.a mechanism configured to provide relative motion between the microwavedevice and the reaction chamber.
 9. The coal combusting system of claim5 wherein the vapor explosion section of the beneficiation sub-system,further comprises: a wash element that is configured to remove and cleanmicroparticles of unprocessed organic-carbon-containing feedstock,lignin fragments, and hemicellulosic fragments from the vapor explosionsection into a fine, sticky mass of biomass with high lignin content,and wherein a blending chamber of the blending sub-section is furtherconfigured to receive fine, sticky mass of biomass to permit lowertemperatures in a compaction chamber formation during formation ofblended compact aggregates.
 10. The coal combusting system of claim 5wherein the processed organic-carbon-containing feedstock has a watersoluble intracellular salt content that is decreased by more than 75 wt% on a dry basis from that of unprocessed organic-carbon-containingfeedstock and the compaction section of the beneficiated sub-system isconfigured to provide at least one rinsing step.
 11. A coal combustionprocess for combusting coal and processed biomass in a coal combustingapparatus with less adverse by-products, comprising the steps: providingcoal feedstock to a first chamber of the coal combusting apparatus, thefirst chamber configured to pulverize coal and feed the coal into thecoal combusting apparatus in a first concentration of feedstock, makinga processed biomass pellet feedstock in a processed biomass system,comprising the steps of: a. inputting into the processed biomass asystem comprising a first and a second subsystem an unprocessedorganic-carbon-containing feedstock that includes free water,intercellular water, intracellular water, intracellular water-solublesalts, and at least some plant cells comprising cell walls that includelignin, hemicellulose, and microfibrils within fibrils; b. passingunprocessed organic-carbon-containing feedstock through the firstsubsystem, a beneficiation sub-system via a beneficiation sub-systemprocess, to result in processed organic-carbon-containing feedstock withcharacteristics that include having an energy density of at least 17MMBTU/ton (20 GJ/MT), a water content of less than 20 wt %, and awater-soluble intracellular salt content that is decreased more than 60wt % on a dry basis from that of the unprocessedorganic-carbon-containing feedstock; and c. passing the processedorganic-carbon-containing feedstock through the second subsystem, apelletizing sub-system via a pelletizing sub-system process, to resultin processed biomass pellets; providing processed biomass pelletfeedstock to a second chamber of the coal combusting apparatus, thesecond chamber configured to pulverize the processed biomass and feedthe processed biomass into the coal combusting apparatus in a secondconcentration of feedstock with the ratio of the first concentration tothe second concentration between 1 to 9 and 9 to 1; passing a gaseouswaste stream of the coal combustion apparatus through at least oneexhaust chamber comprising at least one gas separation sub-systemconfigured to separate at least 50 volume % of carbon dioxide from thegaseous waste stream and create separated carbon dioxide; and passingthe separated carbon dioxide through a gas consumption sub-systemconfigured to receive the separated carbon dioxide gas and consume it inthe making of useful materials.
 12. The process of claim 11 wherein thecoal is a processed biomass pellet or a processed biomass/coal blendedcompact aggregate that comprises coal to processed biomass is in a ratioof concentration of from 1 to 9 to 9 to 1 and, the processed biomasssystem further comprises a blending sub-system that uses a blendingsub-system process, and the.
 13. The process of claim 12 wherein thebeneficiation sub-system process, further comprises the steps of: a.inputting into a beneficiation sub-system reaction chamber unprocessedorganic-carbon-containing feedstock comprising free water, intercellularwater, intracellular water, intracellular water-soluble salts, and atleast some plant cells comprising cell walls that include lignin,hemicellulose, and microfibrils within fibrils; b. exposing thefeedstock to hot solvent under pressure for a time at conditionsspecific to the feedstock to make some regions of the cell wallscomprising crystallized cellulosic fibrils, lignin, and hemicellulosemore able to be penetrable by water-soluble salts without dissolvingmore than 25 percent of the lignin and hemicellulose; c. removing thepressure so as to penetrate the more penetrable regions to create porousfeedstock with open pores in the plant cell walls; and d. pressing theporous feedstock with conditions that include an adjustable compactionpressure versus time profile and compaction time duration, and betweenpressure plates configured to prevent felt from forming and blockingescape from the reaction chamber of intracellular and intercellularwater, and intracellular water-soluble salts, and to create processedbiomass that has a water content of less than 20 wt % and awater-soluble intracellular salt content that is decreased by at least60 wt % on a dry basis from that of unprocessedorganic-carbon-containing feedstock; and the blending sub-systemprocess, further comprises the steps of: e. sizing the particles toreduce the size of coal and processed biomass to a similar size forblending; f. combining properly sized particles of coal and processedbiomass; and g. compressing the blended powder into a multitude ofprocessed biomass/coal blended compact aggregates; the pelletizingsub-system process, further comprises the step of h. compressing theprocessed organic-carbon-containing feedstock to separate it intopellets with discrete units of mass having a longest length of at least0.16 inch (0.41 cm) and a density of at least 37.5 pounds per cubic foot(0.60 grams per cubic centimeter) and collecting an aggregate ofprocessed biomass pellets; the carbon dioxide separation sub-systemprocess, further comprises the steps of i. cooling a gaseous wastestream from the coal combustion apparatus and adding air to reduce thecarbon dioxide concentration to less than 1000 ppm in a cooled gasstream; and j. separating out the carbon dioxide from the cooled gasstream to form separated carbon dioxide; and the carbon dioxideconsumption sub-system, further comprises the steps of: k. inputting theseparated carbon dioxide as feedstock into a carbon dioxide consumptionsub-system with additional feedstock comprising catalysts andco-reactants from a group consisting of water, natural gas and stackacids; and l. exposing the feedstock under heat from waste heat from thecoal consumption apparatus to catalytic electrochemistry to createbeneficial industrial chemicals including glycols, alcohols, olefins,and organic acids.
 14. The process of claim 13 wherein the beneficiationsub-system process, further comprises: removing and cleaning ofmicroparticles of unprocessed organic-carbon-containing feedstock,lignin fragments, and hemicellulosic fragments from the vapor explosionsection into a fine, sticky mass of biomass with high lignin content inthe removing the pressure step, and adding the fine, sticky mass ofbiomass to at least one of the blending sub-system to permit lowertemperatures in the compressing step during formation of processedbiomass/cleaned coal blended compact aggregate or the pelletizingsub-system to permit lower temperatures in the compressing step duringformation of processed biomass pellets.
 15. The process of claim 12wherein the processed biomass is processed biochar with an energydensity of at least 21 MMBTU/ton (25 GJ/MT) and the process, furthercomprises the step of: passing the processed organic-carbon-containingfeedstock through another sub-system, a heating sub-system, to formprocessed biochar.
 16. The process of claim 15 wherein the beneficiationsub-system process, further comprises the steps of: a. inputting into abeneficiation sub-system reaction chamber unprocessedorganic-carbon-containing feedstock comprising free water, intercellularwater, intracellular water, intracellular water-soluble salts, and atleast some plant cells comprising cell walls that include lignin,hemicellulose, and microfibrils within fibrils; b. exposing thefeedstock to hot solvent under pressure for a time at conditionsspecific to the feedstock to make some regions of the cell wallscomprising crystallized cellulosic fibrils, lignin, and hemicellulosemore able to be penetrable by water-soluble salts without dissolvingmore than 25 percent of the lignin and hemicellulose; c. removing thepressure so as to penetrate the more penetrable regions to create porousfeedstock with open pores in the plant cell walls; and d. pressing theporous feedstock with conditions that include an adjustable compactionpressure versus time profile and compaction time duration, and betweenpressure plates configured to prevent felt from forming and blockingescape from the reaction chamber of intracellular and intercellularwater, and intracellular water-soluble salts, and to create processedorganic-carbon-containing feedstock that has a water content of lessthan 20 wt % and a water-soluble intracellular salt content that isdecreased by at least 60 wt % on a dry basis from that of unprocessedorganic-carbon-containing feedstock; the heat generating sub-systemprocess, further comprises the steps of: e. inputting processedorganic-carbon-containing feedstock into an oxygen-deprived reactionchamber configured to heat the processed organic-carbon-containingfeedstock in an atmosphere that contains less than 4 percent oxygen to atemperature sufficient to convert at least some processedorganic-carbon-containing feedstock into processed biogas and processedbiochar; the blending sub-system process, further comprises the stepsof: f. sizing the particles to reduce the size of coal and processedbiomass to a similar size for blending; g. combining properly sizedparticles of coal and processed biomass; and h. compressing the blendedpowder into a multitude of processed biomass/coal blended compactaggregates; the pelletizing sub-system process, further comprises thestep of i. compressing the processed organic-carbon-containing feedstockto separate it into pellets with discrete units of mass having a longestlength of at least 0.16 inch (0.41 cm) and a density of at least 37.5pounds per cubic foot (0.60 grams per cubic centimeter) and collectingan aggregate of processed biomass pellets; the carbon dioxide separationsub-system process, further comprises the steps of j. cooling a gaseouswaste stream from the coal combustion apparatus and adding air to reducethe carbon dioxide concentration to less than 1000 ppm in a cooled gasstream; and k. separating out the carbon dioxide from the cooled gasstream to form separated carbon dioxide; and the carbon dioxideconsumption sub-system, further comprises the steps of: l. inputting theseparated carbon dioxide as feedstock into a carbon dioxide consumptionsub-system with additional feedstock comprising catalysts andco-reactants from a group consisting of water, natural gas and stackacids; and m. exposing the feedstock under heat from waste heat from thecoal consumption apparatus to catalytic electrochemistry to createbeneficial industrial chemicals including glycols, alcohols, olefins,and organic acids.
 17. The process of claim 16 wherein the beneficiationsub-system process, further comprises: removing and cleaning ofmicroparticles of unprocessed organic-carbon-containing feedstock,lignin fragments, and hemicellulosic fragments from the vapor explosionsection into a fine, sticky mass of biomass with high lignin content inthe removing the pressure step, and the blending sub-system, furthercomprises: adding the fine, sticky mass of biomass to the blended powderto permit lower temperatures in the compressing step during formation ofblended compact aggregates.
 18. The process of claim 16 wherein theheating sub-system is an oxygen-deprived thermal sub-system process,further comprises the steps of: a. inputting processedorganic-carbon-containing feedstock into a substantially horizontalsublimating reaction chamber largely contained within a hot box andconfigured to be able to heat from an ambient temperature to anoperating sublimation temperature, operate at a sublimation temperature,and cool from a operating sublimation temperature to an ambienttemperature without leaking any hot product gas fuel from the reactionchamber into the hot box or atmosphere, or leaking any oxygen fromoutside the hot box into the hot box; b. heating the processedorganic-carbon-containing feedstock to a sublimating temperature beforeit is able to form a liquid phase; c. maintaining the temperature at asublimation temperature for a residence time that is as long a time asneeded to convert the processed organic-carbon-containing feedstock toprocessed biogas and processed biochar; and d. separating the processedbiogas from the processed biochar.
 19. The process of claim 16 whereinthe wherein the heating sub-system is an oxygen-deprived thermalsub-system process, further comprises the steps of: a. inputtingprocessed organic-carbon-containing feedstock into a substantiallyvertical sublimating reaction chamber; b. heating processedorganic-carbon-containing feedstock to a sublimating temperature beforeit is able to form a liquid phase; c. maintaining the temperature at asublimation temperature for a residence time that is as long a time asneeded to convert the processed organic-carbon-containing feedstock toprocessed biogas and processed biochar; and d. separating the processedbiogas from the processed biochar.
 20. The process of claim 11 whereinthe beneficiation sub-system process and the pelletizing sub-systemprocess, further comprises the steps of: a. inputting into a reactionchamber unprocessed organic-carbon-containing feedstock comprising freewater, intercellular water, intracellular water, intracellularwater-soluble salts, and at least some plant cells comprising cell wallsthat include lignin, hemicellulose, and microfibrils within fibrils; b.exposing the feedstock to hot solvent under pressure for a time atconditions specific to the feedstock to make some regions of the cellwalls comprising crystallized cellulosic fibrils, lignin, andhemicellulose more able to be penetrable by water-soluble salts withoutdissolving more than 25 percent of the lignin and hemicellulose; c.removing the pressure so as to penetrate the more penetrable regions tocreate porous feedstock with open pores in the plant cell walls; and d.pressing the porous feedstock with conditions that include an adjustablecompaction pressure versus time profile and compaction time duration,and between pressure plates configured to prevent felt from forming andblocking escape from the reaction chamber of intracellular andintercellular water, and intracellular water-soluble salts and to createprocessed biomass that has a water content of less than 20 wt %, awater-soluble intracellular salt content that is decreased by at least60 wt % on a dry basis over that of unprocessedorganic-carbon-containing feedstock, and a cost per weight of removingthe water and water-soluble salt that is reduced to less than 60% of thecost per weight of similar water removal from known mechanical, knownphysiochemical, or known thermal processes, the blending sub-systemprocess, further comprises the steps of: e. sizing the particles toreduce the size of coal and processed biomass to a similar size forblending; f. combining properly sized particles of coal and processedbiomass; and g. compressing the blended powder into a multitude ofprocessed biomass/coal blended compact aggregates; ad the pelletizingsub-system process, further comprises the step of h. compressing theprocessed organic-carbon-containing feedstock to separate it intopellets with discrete units of mass having a longest length of at least0.16 inch (0.41 cm) and a density of at least 37.5 pounds per cubic foot(0.60 grams per cubic centimeter) and collecting an aggregate ofprocessed biomass pellets; the carbon dioxide separation sub-systemprocess, further comprises the steps of i. cooling a gaseous wastestream from the coal combustion apparatus and adding air to reduce thecarbon dioxide concentration to less than 1000 ppm in a cooled gasstream; and j. separating out the carbon dioxide from the cooled gasstream to form separated carbon dioxide; and the carbon dioxideconsumption sub-system, further comprises the steps of: k. inputting theseparated carbon dioxide as feedstock into a carbon dioxide consumptionsub-system with additional feedstock comprising catalysts andco-reactants from a group consisting of water, natural gas and stackacids; and l. exposing the feedstock under heat from waste heat from thecoal consumption apparatus to catalytic electrochemistry to createbeneficial industrial chemicals including glycols, alcohols, olefins,and organic acids.